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Home >> Cadillac >> 2021 >> CT4 Sport, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 170 (Engine Mechanical - 2.7L (L3B) - Repair Instructions (2 Of 3)) >> Repair Instructions >> Cylinder Head Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2022 Cadillac CT4. However, it is still accessible from the selected car via links, so may be relevant.
  1. GM5064715
    NOTE:

    Do NOT install the fuel injector nozzle housing seals until AFTER the injectors are installed on the fuel rail.

    Fuel Injector Seal Spacer (1) - Install NEW [4x]

    Fuel Injector Seal (2) - Install NEW [4x]

    2. NOTE:

    Arrows show proper orientation to install the bushing. The bushing will fit flush against the injector.

  2. Fuel Injector Bushing (3) - Install NEW [4x]
  3. GM5064709
    CAUTION:

    During the installation of the fuel rail and injector assembly, ensure that the fuel injectors are positioned straight into the injector opening. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.

    NOTE:

    Use a fiberless, lint free swab to apply the lubrication to the O-ring before installation.

    Holding the largest diameter/body (2) of the injector only, insert the injector assembly (2) into the fuel rail. Ensure correct orientation of the electrical connector.

    4. CAUTION:

    Ensure the fuel injector retainer is properly installed. Failure to completely install the retainers may degrade fuel injection system performance or cause system malfunction.

  4. Fuel Injector Retainer (1) - Install NEW
  5. Repeat for remaining injectors until all are installed and retained in fuel rail.
  6. GM4840511
    NOTE:

    DO NOT use any type of lubricant when installing the NEW combustion seals on the fuel injector tip.

    Install EN-51955-1  long protector (1) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW seal (2) on EN-51955-1  long protector (1).

  7. Using EN-51955-4  pusher (3), install the seal (2) into the recessed area (4) of the fuel injector, then remove the EN-51955-1  long protector.
  8. Compress the seal (2) using EN-51955-3  pre-sizer (5).
  9. Using EN-51955-5  sizer (6), resize the seal.
  10. Install EN-51955-2  short protector (7) onto the fuel injector tip. Place a second NEW seal (8) on EN-51105-2  short protector (7).
  11. Using EN-51955-4  pusher (3), install the seal (8) into the remaining recessed area (9) of the fuel injector, then remove EN-51105-2  short protector.
  12. Compress the seal (8) using EN-51955-3  pre-sizer (5).
  13. Using EN-51955-5  sizer (6), resize the seal.
  14. If the seals are not installed correctly, remove the incorrect seal and replace with a NEW seal.
  15. GM5026478

    Positive Crankcase Ventilation Oil Separator Gasket (3) - Install NEW

  16. Positive Crankcase Ventilation Oil Separator (2) - Install
    17. CAUTION:

    Fastener Caution

  17. Positive Crankcase Ventilation Oil Separator Bolt (1) - Install and hand tighten [7x] - Fastener Specifications
  18. GM5022863

    Cylinder Head Gasket (1) - Install NEW

  19. Cylinder Head (2) - Install
    20. CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

  20. Cylinder Head Bolt (3) - Install NEW and hand tighten [10x]
  21. Cylinder Head Bolt (4) - Install NEW and hand tighten [3x]
  22. Cylinder Head Bolt (5) - Install NEW and hand tighten [3x]
  23. Cylinder Head Bolt (6) - Install NEW and hand tighten [2x]
  24. Tighten the 18 cylinder head bolts (3, 4, 5, 6) in sequence. Fastener Specifications
  25. GM5043852

    Use low VOC brake cleaner to ensure the surface areas are clean. Adhesives, Fluids, Lubricants, and Sealers

  26. EN-46109  Engine Front Cover Installation Guide Pins (2) - Install
  27. Apply a 3 mm wide RTV bead along the edge of the cylinder head. Path is perpendicular to the crank axis. Bead is centered 2.5 mm back from front edge of head. Bead runs the entire length of sealing surface across sealing land on both sides.
  28. Camshaft Cover Gasket (1) - Install NEW
  29. GM5022866

    Camshaft Cover (1) - Install

    NOTE:

    Ensure the EN-52462-A  Camshaft Tool is installed and camshafts are in the timed position.

  30. Rock the camshaft carrier back and fourth to seat the camshaft carrier cover onto the two dowels in the cylinder head sealing surface.
  31. EN-46109  Engine Front Cover Installation Guide Pins (2) - Remove
  32. GM5043854

    Camshaft Cover Bolt (1) - Install and hand tighten [5x]

  33. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
    1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
    2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  34. Camshaft Cover Stud (2, 3) - Install and hand tighten [18x]
  35. Camshaft Cover Bolt (1) - Tighten in sequence [4x] - Fastener Specifications
  36. Camshaft Cover Stud (2, 3) - Tighten in sequence [18x] - Fastener Specifications
  37. GM5004079

    Timing Chain (4) - Install

  38. Crankshaft Sprocket (3) - Install
  39. Timing Chain Guide (2) - Install
  40. Timing Chain Guide Bolt (1) - Install and tighten [2x] - Fastener Specifications
  41. GM5004068

    Timing Chain Guide (5) - Install

  42. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
    1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
    2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  43. Timing Chain Guide Bolt (4) - Install and tighten - Fastener Specifications
  44. Timing Chain Tensioner Gasket (3) - Install NEW
  45. Timing Chain Tensioner (2) - Install
  46. Timing Chain Tensioner Bolt (1) - Install and tighten [2x] - Fastener Specifications
  47. EN-46112  Tensioner Retraction Pins (6) - Remove
  48. GM5257435
    NOTE:

    Lubricate under the washer surface.

    Lubricate the NEW camshaft position actuator valve solenoid bolts (1) with clean engine oil where indicated. Adhesives, Fluids, Lubricants, and Sealers

  49. GM5299894

    Install the exhaust camshaft position actuator (3) and the intake camshaft position actuator (4) before installing the tool.

  50. GM5257330

    Install and hand tighten the NEW camshaft position actuator valve solenoid bolt (1).

  51. GM5256386
    NOTE:

    Ensure the camshaft carrier and cylinder head face are clean and free from RTV prior to installing the EN-52461-200  Adapter 675T of Cam Phaser Torque Reaction Tool.

    EN-52461-200  Adapter 675T of Cam Phaser Torque Reaction Tool (2) - Install [2x]

  52. Install and tighten the two EN-52461-200  Adapter 675T of Cam Phaser Torque Reaction Tool bolts (3) enough to secure the EN-52461-200  Adapter 675T of Cam Phaser Torque Reaction Tool (2) to the cylinder head.
  53. GM5257213

    EN-52461  Camshaft Actuator Holder (1) @ EN-52461-200  Adapter 675T of Cam Phaser Torque Reaction Tool (2) - Install

  54. Install and tighten the two EN-52461  Camshaft Actuator Holder bolts (3).
  55. GM5257414
    CAUTION:

    Hold the camshaft position actuator firmly and squarely during camshaft position actuator valve solenoid bolt removal/installation. Failure to do so may result in damage to the inside of the camshaft position actuator.

    NOTE:

    Pressure must be applied towards the engine on the EN-52461  Camshaft Actuator Holder at points (3) prior to and during any time the following two conditions are simultaneously met.

    • The camshaft position actuator valve solenoid bolt is loosened or removed.
    • The EN-52461  Camshaft Actuator Holder bolts (2, 3) are loosened.

    Shift the slack in the timing chain to be taken up by the timing chain tensioner.

    1. Use a wrench to turn the EN-52461  Camshaft Actuator Holder (1) counter-clockwise 6 N.m 53 lb in, then hold.
    2. Tighten the EN-52461  Camshaft Actuator Holder bolt (2) to lock the intake actuator securely in place.
    3. Remove the wrench from EN-52461  Camshaft Actuator Holder (1).
    4. Use a wrench to turn the EN-52461  Camshaft Actuator Holder (4) counter-clockwise 6 N.m 53 lb in, then hold.
    5. Tighten the EN-52461  Camshaft Actuator Holder bolt (3) to lock the exhaust actuator securely in place.
    6. Remove the wrench from EN-52461  Camshaft Actuator Holder (4).
  56. GM5257299

    Tighten the NEW camshaft position actuator valve solenoid bolt (1). Fastener Specifications

  57. GM5257293

    Loosen the EN-52461  Camshaft Actuator Holder bolts (2) to un-lock the actuators.

  58. Disengage the tangs of the EN-52461  Camshaft Actuator Holder (1) from the intake and exhaust camshaft position actuator slots.
  59. GM5257213

    Remove the two EN-52461  Camshaft Actuator Holder bolts (3).

  60. EN-52461  Camshaft Actuator Holder (1) @ EN-52461-200  Adapter 675T of Cam Phaser Torque Reaction Tool (2) - Remove
  61. GM5256386

    Remove the two EN-52461-200  Adapter 675T of Cam Phaser Torque Reaction Tool bolts (3).

  62. EN-52461-200  Adapter 675T of Cam Phaser Torque Reaction Tool (2) - Remove [2x]
  63. Rotate both handles (4) of the EN-52462-A  Camshaft Tool towards the front of the engine.
  64. GM5256287

    Loosen and disengage the EN-52462-A  Camshaft Tool bolt (2) from camshaft carrier.

  65. EN-52462-A  Camshaft Tool (1) - Remove
  66. GM5002064

    Clean and apply sealant to the camshaft cover core hole plug (1) [2x]. Adhesives, Fluids, Lubricants, and Sealers

  67. Camshaft Cover Core Hole Plug (1) - Install and tighten [2x] - Fastener Specifications
  68. Camshaft Carrier Bolt (2) - Install and tighten - Fastener Specifications
  69. GM5021096

    EN-52483  Cover Installation Guide Pins (4) - Install

  70. GM5045208
    NOTE:

    The sealing surface must be clean and free of contaminants prior to applying the RTV sealant. Do not touch the sealing surface once it has been cleaned.

    Clean the sealing surface of the NEW engine front cover with low VOC brake cleaner, then wipe dry with a clean lint free cloth.

  71. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
    72. NOTE:

    Do not allow RTV to skin over. The engine front cover must be installed within 8 minutes of RTV application.

  72. Apply a bead of RTV (1) to the NEW engine front cover. Adhesives, Fluids, Lubricants, and Sealers
  73. GM5021096
    NOTE:

    Leave the seal protector that is supplied with the new engine front cover in place prior to installation. The crankshaft sprocket will push the seal protector out of the engine front cover as it is installed. Inspect the perimeter of the seal once the NEW engine front cover is completely seated to ensure the lip of the seal is not folded over itself.

    Engine Front Cover (2) - Install NEW

  74. Engine Front Cover Bolt (3) - Install and hand tighten [8x]
  75. EN-52483  Cover Installation Guide Pins (4) - Remove
  76. Engine Front Cover Bolt (3) - Install and hand tighten [2x]
  77. Engine Front Cover Bolt (3) - Tighten in sequence [10x] - Fastener Specifications
  78. GM5164169
    NOTE:

    The timing pin (3) is installed into the flexplate for engine timing procedures, it can be damaged if torque is applied to the flexplate with the timing pin engaged. The pin must be placed in the retracted position before torque is applied to the flexplate.

    Install the slide (4) of the EN-52476  Flywheel Lock and Alignment Tool.

  79. GM5003927

    Crankshaft Balancer (2) - Install

  80. Crankshaft Balancer Bolt (1) - Install NEW and tighten - Fastener Specifications
  81. GM5004054

    Timing Belt Front Upper Cover Seal (4) - Install NEW

  82. Apply a dollop of RTV on the T-joint of the camshaft carrier and cylinder head. Adhesives, Fluids, Lubricants, and Sealers
  83. Timing Chain Upper Cover (3) - Install
  84. Timing Chain Upper Cover Bolt (1) - Install and tighten [9x] - Fastener Specifications
  85. Timing Chain Upper Cover Bolt (2) - Install and tighten - Fastener Specifications
  86. GM5646819

    Camshaft Position Actuator Magnet Gasket (3) - Install NEW

  87. Camshaft Position Actuator Magnet (2) - Install
  88. Camshaft Position Actuator Solenoid Valve Bolt (1) - Install and tighten [2x] - Fastener Specifications
  89. GM5646821

    Camshaft Position Actuator Magnet Gasket (3) - Install NEW

  90. Camshaft Position Actuator Magnet (2) - Install
  91. Camshaft Position Actuator Solenoid Valve Bolt (1) - Install and tighten [2x] - Fastener Specifications
  92. GM5022674
    NOTE:
    • The camshaft MUST be at the base circle position before the fuel pump is installed.
    • At the base circle position, the EN-52443  High Pressure Fuel Pump Alignment Tool will sit flush with the cylinder head.

    Install the EN-52443  High Pressure Fuel Pump Alignment Tool and turn the crankshaft until the camshaft lobe is at the base circle position.

  93. Remove the EN-52443  High Pressure Fuel Pump Alignment Tool.
  94. Lubricate the valve lifter follower (4) with clean engine oil.
  95. Valve Lifter Follower (4) - Install
  96. Fuel Pump Seal (3) - Install NEW
  97. Fuel Pump (2) - Install
    98. CAUTION:

    Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.

  98. Fuel Pump Stud (1) - Install and tighten [2x] - Fastener Specifications
  99. Electrical Connector @ Fuel Pump - Connect
  100. GM5133846
    NOTE:

    Hand place the fuel injection fuel rail into the position on the cylinder head.

    Fuel Injection Fuel Rail (1) - Move into position

  101. Install the four fuel injection fuel rail bolts (2) [2x] hand tight only, DO NOT apply any torque.
  102. Tighten the two outer fuel injection fuel rail bolts by alternating in steps of 1/2 turn, until the fuel injection fuel rail (1) is fully seated.
  103. Fuel Injection Fuel Rail Bolt (2) - Tighten [4x] - Fastener Specifications
  104. Electrical Connector (3) - Connect [3x]
  105. GM5132483
    WARNING:

    The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

    Connect all electrical connectors around the fuel rail and knock sensors.

  106. Fuel Injection Fuel Rail Noise Shield (1) - Install
  107. GM5417288

    Auxiliary Generator Battery Jumper Cable (2) - Install

  108. Battery Positive Cable Nut (1) @ Starter Solenoid - Install and tighten - Fastener Specifications
  109. Electrical Connector (4) - Connect
  110. Starter (3) - Install
  111. GM5417249

    Starter Bolt (2) - Install and tighten [2x] - Fastener Specifications

  112. Starter Stud (1) - Install and tighten - Fastener Specifications
  113. GM5417233

    Auxiliary Generator Battery Jumper Cable - Install

  114. Auxiliary Generator Battery Jumper Cable Terminal Nut (1) - Install and tighten - Fastener Specifications
  115. Retainer (3) - Engage
  116. GM5144023

    Engine Coolant Flow Control Valve Seal (2) - Install NEW

  117. Install the engine coolant flow control valve (1) into the thermostat bypass hose and then position the engine coolant flow control valve to the engine block.
  118. GM5144011

    Engine Coolant Flow Control Valve Bolt (1) - Install and tighten [5x] - Fastener Specifications

  119. GM5143899

    Engine Coolant Temperature Sensor Electrical Connector (2) @ Engine Coolant Flow Control Valve - Connect

  120. Electrical Connector (1) @ Engine Coolant Flow Control Valve - Connect [2x]
  121. GM5517143

    Slide the hose clamp (3) back into position and engage the clamp. Hose Clamp Replacement Guidelines - Spring Type

  122. Thermostat Bypass Hose (2) @ Engine Coolant Flow Control Valve - Install
  123. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  124. GM5143856

    Radiator Inlet Hose (4) @ Engine Coolant Flow Control Valve - Install

  125. Engine Oil Cooler Coolant Inlet Hose (3) @ Engine Coolant Flow Control Valve - Install
  126. Engine Coolant Flow Control Valve Hose (2) @ Engine Coolant Flow Control Valve - Install
  127. Hose Clamp (1) - Engage [3x] - Hose Clamp Replacement Guidelines - Spring Type
  128. GM5141724

    Engine Coolant Thermostat Housing Bracket Bolt (1) - Install and tighten - Fastener Specifications

  129. GM5135183

    Exhaust Manifold Outlet Pipe Bolt (1) - Install and tighten - Fastener Specifications

  130. GM5045008

    Intake Manifold Gasket (3) - Install NEW

  131. Crankcase Vent Passage Seal (4) - Install NEW
  132. GM5145544

    Intake Manifold (2) - Install

  133. Intake Manifold Bolt (1) - Install and hand tighten [6x]
  134. Intake Manifold Bolt (1) - Tighten in sequence [6x] - Fastener Specifications
  135. GM5145608

    Intake Manifold Cover (1) - Install

  136. GM5402098

    Evaporative Emission Canister Purge Pump (2) - Install

  137. Evaporative Emission Canister Purge Pump Bolt - Install and tighten - Fastener Specifications
  138. GM5517398

    Wiring Harness Retainer (1) @ Evaporative Emission Canister Purge Pump Bracket (2) - Connect

  139. GM5003920

    Oil Level Indicator Tube Seal (3) - Install NEW

  140. Oil Level Indicator Tube (2) - Install
  141. Oil Level Indicator Tube Bracket Bolt (1) - Install and tighten - Fastener Specifications
  142. Oil Level Indicator (4) - Install
  143. Install the engine support fixture. Engine Support Fixture
  144. GM5491648

    Engine Mount Nut (1) - Remove

  145. Use the EN-51007  Engine Support Fixture to raise the engine off the engine mount.
  146. GM5491651

    Engine Mount Bracket Bolt (1) - Remove and DISCARD [4x]

  147. GM5495033

    Engine Mount Bracket (1) - Remove

    148. CAUTION:

    Phenolic spacer must be present to prevent galvanic/corrosive reaction and/or excessive temperature conduction between engine mount bracket and engine mount. Replace mount if phenolic spacer is missing or damaged. Failure to ensure phenolic spacer is intact and not damaged can lead to premature failure of engine mount and/or engine mount bracket.

  148. Ensure the phenolic spacer remains in place.
  149. GM5918235

    Turbocharger Stud (1) - Install NEW and tighten [2x] - Fastener Specifications

  150. GM5004022
    WARNING:

    When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury.

    Turbocharger Oil Return Pipe Gasket (5) - Install NEW

  151. Turbocharger Oil Feed Pipe Gasket (4) - Install NEW
  152. Turbocharger Oil Return Pipe Gasket (3) - Install NEW
  153. Turbocharger Oil Feed Pipe (2) @ Compressor Air Intake Turbocharger - Install
  154. Turbocharger Oil Feed Pipe Bolt (1) @ Compressor Air Intake Turbocharger - Install and tighten [2x] - Fastener Specifications
  155. GM5146550

    Turbocharger Gasket (2) - Install NEW

  156. Turbocharger Assembly (1) - Install
  157. GM5146546

    Turbocharger Nut (1) - Install NEW and hand tighten [2x]

  158. Turbocharger Bolt (2) - Install NEW and hand tighten [2x]
  159. Tighten the 2 turbocharger nuts (1) and the 2 turbocharger bolts (2) in sequence. Fastener Specifications
  160. GM5146481

    Turbocharger Oil Feed Pipe Bolt (4) - Install and tighten [4x] - Fastener Specifications

  161. Turbocharger Brace (3) - Install
  162. Turbocharger Bracket Bolt (2) - Install and tighten [2x] - Fastener Specifications
  163. Turbocharger Brace Nut (1) - Install and tighten - Fastener Specifications
  164. GM5156836

    Positive Crankcase Ventilation Tube (1) - Install NEW

  165. GM5517316

    Reposition the front axle vent hose (3) and electrical harness (4).

  166. Electrical Connector (2) - Connect [2x]
  167. Retainer (1) - Connect [3x]
  168. GM5395366

    Turbocharger Coolant Feed and Return Pipe Gasket (2) - Install NEW

  169. Turbocharger Coolant Feed and Return Pipe (1) - Install
  170. GM5395358

    Turbocharger Coolant Feed and Return Pipe Bolt (1) - Install [2x] - Fastener Specifications

  171. GM5395343

    Turbocharger Coolant Feed Hose (2) @ Turbocharger Coolant Feed and Return Pipe - Install

  172. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  173. GM5395335

    Turbocharger Coolant Feed and Return Pipe (2) @ Exhaust Manifold Outlet Pipe - Install

  174. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  175. GM5395337

    Compressor Air Intake Turbocharger Wastegate Actuator Rod (3) @ Turbocharger Wastegate Actuator - Connect

  176. Compressor Air Intake Turbocharger Wastegate Actuator Link Clip (2) - Install
  177. Compressor Air Intake Turbocharger Wastegate Actuator Link Spring (1) - Install
  178. GM5403768

    Catalytic Converter Gasket (3) - Install NEW

  179. Exhaust Pipe Clamp (2) - Install NEW but do NOT tighten.
    180. NOTE:

    Ensure that the catalytic converter gasket is fully seated on the warm up three-way catalytic converter inlet flange.

  180. Warm Up Three-Way Catalytic Converter (1) - Install
  181. GM5442538

    Catalytic Converter Brace (3) - Install

  182. Catalytic Converter Brace Bolt (2) - Install and tighten [2x] - Fastener Specifications
  183. Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  184. GM5403738
    NOTE:

    Inspect on all sides of the warm up three-way catalytic converter to verify it is fully seated prior to tightening the exhaust pipe clamp.

    Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications

  185. GM5399464

    Front Crossmember Brace (2) - Install

  186. Front Crossmember Brace Nut (1) - Install and tighten [4x] - Fastener Specifications
  187. GM5394598

    Catalytic Converter Gasket (2) - Install NEW

  188. Exhaust Muffler (1) - Install
  189. GM5309211

    Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Install

  190. Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Install
  191. GM5309202

    Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Install

  192. Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Install
  193. GM5394596

    Electrical Connector (1) @ Exhaust Control Valve Actuator - Connect [2x]

  194. GM5309188

    Catalytic Converter Nut (1) - Install and tighten [2x] - Fastener Specifications

  195. GM5400756

    Floor Panel Reinforcement (2) - Install

  196. Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Install and tighten [6x] - Fastener Specifications
  197. GM5399124
    CAUTION:

    Refer to Component Fastener Tightening Caution .

    NOTE:

    A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound already applied to the threads. IF a sensor is removed and is to be reinstalled, the threads MUST have an anti-seize compound applied before installation. Adhesives, Fluids, Lubricants, and Sealers

    Using the appropriate tool, install the heated oxygen sensor (1). Fastener Specifications

  198. Connect the electrical connector.
  199. GM5495033

    Engine Mount Bracket (1) - Install

  200. GM5491651
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

    Engine Mount Bracket Bolt (1) - Install NEW and tighten [4x] - Fastener Specifications

  201. Use the EN-51007  Engine Support Fixture to lower the engine onto the engine mount.
  202. GM5491648

    Engine Mount Nut (1) - Install NEW and tighten - Fastener Specifications

  203. GM5407967

    Water Pump Cover (2) - Install

  204. Water Pump Cover Bolt (1) - Install and tighten [3x] - Fastener Specifications
  205. GM5494001

    Retainer (1) - Install

  206. GM5395459

    Turbocharger Heat Shield (1) - Install

  207. GM5395458

    Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications

  208. GM5395457

    Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications

  209. GM5135192

    Exhaust Manifold Outlet Pipe Gasket (3) - Install NEW

  210. Exhaust Manifold Outlet Pipe (2) - Install
  211. Exhaust Manifold Outlet Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
  212. GM5475553

    Radiator Surge Tank Inlet Hose (2) - Install

  213. Radiator Surge Tank Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  214. Radiator Surge Tank Inlet Hose Clip (3) - Install [4x]
  215. GM5472821

    Radiator Surge Tank Inlet Hose (2) - Install

  216. Radiator Surge Tank Inlet Hose Clamp (1) - Engage [3x] - Hose Clamp Replacement Guidelines - Spring Type
  217. GM5399121
    CAUTION:

    Refer to Component Fastener Tightening Caution .

    NOTE:

    A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound already applied to the threads. IF a sensor is removed and is to be reinstalled, the threads MUST have an anti-seize compound applied before installation. Adhesives, Fluids, Lubricants, and Sealers

    Using the appropriate tool, install the heated oxygen sensor (1). Fastener Specifications

  218. Connect the electrical connector.
  219. GM5003904

    Belt Idler Pulley (1) - Install and tighten - Fastener Specifications

  220. GM5500583

    Drive Belt Tensioner (4) - Install

  221. Drive Belt Tensioner Bolt (3) - Install and tighten [2x] - Fastener Specifications
  222. GM5500497

    Drive Belt Idler Pulley (2) - Install and tighten - Fastener Specifications

  223. GM5156329

    Position the drive belt (2) onto all but one of the idler pulleys.

  224. Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise, then hold tension.
  225. Install the drive belt (2) onto the last idler pulley. Check to ensure that the drive belt is centered on each pulley, and fully seated into ribbed pulleys.
  226. Slowly release tension from the drive belt tensioner (1).
  227. Inspect the drive belt (2) again to ensure centered on each pulley.
  228. GM5399142

    Charge Air Cooler Inlet Air Tube (2) @ Turbocharger (3) - Install

  229. Retainer Spring (1) - Engage
  230. GM5399157

    Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Install

  231. Retainer Spring (1) - Engage
  232. GM5156644

    Engine Wiring Harness Bracket (2) - Install

  233. Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  234. GM5156637

    Electrical Connector (2) @ Camshaft Carrier (3) - Connect [6x]

  235. Electrical Connector (1) @ Camshaft Carrier (3) - Connect [6x]
  236. GM5404599

    Fuel Feed Intermediate Pipe (2) - Install NEW

  237. Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
  238. GM5404598

    Nut @ Fuel Feed Intermediate Pipe (1) - Install and hand tighten [2x]

  239. Nut @ Fuel Feed Intermediate Pipe (1) - Tighten [2x] - Fastener Specifications
  240. GM5478583
    WARNING:

    The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

    Fuel Pump Insulator (1) - Install

  241. GM5478561

    Fuel Injection Pump Bracket (3) - Install

  242. Fuel Pump Shield Bolt (2) - Install and tighten [2x] - Fastener Specifications
  243. Fuel Pump Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
  244. GM5512093

    Retainer (1) - Install

  245. GM5404490

    Ignition Coil (2) - Install [4x]

  246. Ignition Coil Bolt (1) - Install and tighten [8x] - Fastener Specifications
  247. GM5457786

    Upper Intake Manifold Bracket (2) - Install

  248. Upper Intake Manifold Cover Nut (1) - Install and tighten [2x] - Fastener Specifications
  249. GM5457857

    Radiator Surge Tank Inlet Hose Clip (2) @ Upper Intake Manifold Bracket (3) - Install

  250. Upper Intake Manifold Cover Nut (1) - Install and tighten [2x] - Fastener Specifications
  251. GM5159484

    Retainer (1) @ Upper Intake Manifold Bracket (2) - Install [4x]

  252. GM5457059

    Wiring Harness (2) - Reposition

  253. Electrical Connector (1) - Connect [5x]
  254. GM5129475

    Install the fuel feed pipe (1) from the fuel pump and the fuel feed pipe - underbody. Metal Collar Quick Connect Fitting Service

  255. GM5129466

    Fuel Feed Pipe Bolt (1) - Install and tighten - Fastener Specifications

  256. GM5399073

    Air Cleaner Assembly (1) - Install

  257. GM5399053

    Air Cleaner Bolt (1) - Install and tighten - Fastener Specifications

  258. Connect the electrical connector and install all wiring harnesses to the air cleaner assembly.
  259. GM5398967

    Air Cleaner Outlet Duct (1) - Install

  260. GM5398955

    Positive Crankcase Ventilation Tube (3) - Connect - Plastic Collar Quick Connect Fitting Service

  261. Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] -
  262. Connect the electrical connector.
  263. GM5395515

    Evaporative Emission Canister Purge Tube (1) - Install - Plastic Collar Quick Connect Fitting Service

  264. Remove the engine support fixture. Engine Support Fixture
  265. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
  266. Fill the engine oil to the proper level with NEW engine oil. Engine Oil and Oil Filter Replacement (RWD) 
    267. WARNING:

    Refer to Diesel/Gasoline Vapors Warning .

    WARNING:

    Refer to Safety Glasses Warning .

  267. Pressurize the fuel system and inspect for leaks.
  268. Inspect the exhaust system for leaks.
  269. GM5512092

    Positive Crankcase Ventilation Tube (4) - Connect - Plastic Collar Quick Connect Fitting Service

  270. Engine Wiring Harness (3) - Reposition
  271. Retainer (2) - Install [5x]
  272. Electrical Connector (1) - Connect [2x]
  273. GM5456829
    NOTE:

    Ensure the intake manifold cover insulator retainers fully engage the intake manifold cover studs.

    Intake Manifold Cover Insulator (1) - Install

  274. GM5456746

    Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications

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