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Home >> Cadillac >> 2021 >> CT4 Sport, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 199 (Engine Mechanical - 3.6L (LF4) - Repair Instructions (4 Of 4)) >> Repair Instructions >> Engine Replacement (with MHU) >> Installation Procedure

Installation Procedure

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  1. Before continuing, lubricate the cylinder head bore with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
  2. GM5871785
    NOTE:
    • The camshaft MUST be at the base circle position before the fuel pump is installed.
    • At the base circle position, the EN-48896  High Pressure Fuel Pump Installation Alignment Gauge will sit flush with the cylinder head.

    Install the EN-48896  High Pressure Fuel Pump Installation Alignment Gauge (2) and turn the crankshaft until the camshaft lobe is at the base circle position.

  3. Remove the EN-48896  High Pressure Fuel Pump Installation Alignment Gauge (1).
  4. GM5871517

    Lubricate the NEW fuel pump housing seal (5) with clean engine oil and install it on the fuel pump. Adhesives, Fluids, Lubricants, and Sealers

    5. CAUTION:

    This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

    NOTE:
    • ALWAYS make sure the fuel pump bolt retainers are present before installing the fuel pump bolts.
    • If ANY fuel pump bolt retainers are missing or NOT suitable for reuse, replace the retainers as necessary.
    • The locator tab on the fuel pump bracket gasket should be positioned away from the engine block.
  5. Install the fuel pump bolts (1) and NEW fuel pump bracket gasket (4) to the fuel pump (2).
  6. Lubricate the valve lifter follower (3) with clean engine oil and install it into the cylinder head bore. Adhesives, Fluids, Lubricants, and Sealers
  7. Install the fuel pump assembly (2) into the cylinder head and start the fuel pump bolts (1) by hand.
    8. CAUTION:

    Refer to Fastener Caution .

    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.

  8. Fuel Pump Bolt (1) - Tighten [2x] - Fastener Specifications
  9. GM5877428

    Knock Sensor Bank 2 (2) - Install

  10. Knock Sensor Bolt (1) - Install and hand tighten - Fastener Specifications
  11. Connect the knock sensor electrical connector.
  12. GM5877415

    Knock SensorBank 1 (2) - Install

  13. Knock Sensor Bolt (1) - Install and hand tighten - Fastener Specifications
  14. Connect the knock sensor electrical connector.
  15. GM5044263
    NOTE:

    Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.

    Install EN 49245-1  long protector (3) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW seal (2) on EN-49245-1  long protector.

  16. Using EN-49245-3  pusher (1), install the seal into the second recessed area (4) of the fuel injector.
    17. NOTE:

    The EN-49245-4  sizer is two sided, and either direction will size the seal correctly.

  17. Compress the seal with your fingers, then resize the seal using the EN-49245-4  sizer (5).
  18. Inspect the NEW fuel injector nozzle housing seals on ALL injectors, ensuring the seals are seated correctly. All seals must be fixed tight, and accurately to the fuel injector nozzle, with no overlap, buckling, or corrugation present. Replace any seal that is incorrectly seated on the fuel injector nozzle with a NEW seal.
  19. GM5044264
    NOTE:

    Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.

    Install EN-49245-2  short protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN-49245-2  short protector.

  20. Using EN-49245-3  pusher (1), install the seal into the first recessed area (4) of the fuel injector.
    21. NOTE:

    The EN-49245-4  sizer is two sided, and either direction will size the seal correctly.

  21. Compress the seal with your fingers, then resize the seal using the EN-49245-4  sizer (5).
  22. GM5876237
    NOTE:

    The fuel injection fuel rail bolts are retained into the rails using keepers. Care should be taken to ensure that the threadlock is installed after the fasteners are installed in their bore.

    If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Remove loose debris from internal and external threads using compressed air.
    4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
    23. NOTE:

    Start the fuel injection fuel rail bolts by hand then draw the injector rail down evenly prior to tightening.

  23. Fuel Injection Fuel Rail Bolt (1) - Install and tighten [4x] - Fastener Specifications
  24. GM5876881
    NOTE:

    The fuel injection fuel rail bolts are retained into the rails using keepers. Care should be taken to ensure that the threadlock is installed after the fasteners are installed in their bore.

    If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Remove loose debris from internal and external threads using compressed air.
    4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
    25. NOTE:

    Start the fuel injection fuel rail bolts by hand then draw the injector rail down evenly prior to tightening.

  25. Fuel Injection Fuel Rail Bolt (1) - Install [4x]
  26. Install the fuel injection fuel rail assembly (2) to the cylinder head.
  27. Fuel Injection Fuel Rail Bolt (1) - Tighten [4x] - Fastener Specifications
  28. Connect the electrical wiring harness connectors to the fuel rail as needed.
  29. GM5869756
    NOTE:

    Do NOT reuse the fuel feed intermediate pipe. If the fuel feed intermediate pipe fittings are loosened or the pipes are removed, the pipes MUST be replaced.

    Fuel Feed Intermediate Pipe (1) - Install NEW

    1. Slide fuel feed pipe fitting nuts (2) back along fuel feed intermediate pipe (1) to reveal the formed ends (3) of the fuel feed pipe.
    2. Carefully install the formed ends (3) of the fuel feed intermediate pipe into the sockets of the fuel pump (4) and the fuel injection fuel rails (5).
    3. Hold the pipe firmly in place and hand tighten the fuel feed pipe fitting nuts (2) onto the threads on the fuel injection fuel rails (5) and the fuel pump (4).
  30. Fuel Feed Intermediate Pipe Nut (2) @ Fuel Feed Intermediate Pipe (1) - Tighten [3x] - Fastener Specifications
  31. GM5861168

    Ignition Coil-Bank 2 (2) - Install [3x]

  32. Ignition Coil Bolt (1) - Install and tighten [3x] - Fastener Specifications
  33. Connect the electrical connectors.
  34. GM5861128

    Ignition Coil-Bank 1 (2) - Install [3x]

  35. Ignition Coil Bolt (1) - Install and tighten [3x] - Fastener Specifications
  36. Connect the electrical connectors.
  37. GM5864683

    Lower Intake Manifold Gasket (2) - Install NEW [6x]

  38. Intake Manifold (1) - Install
  39. GM5864681

    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. Remove loose debris from internal and external threads using compressed air.
    4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers
  40. Lower Intake Manifold Bolt (1) - Install and tighten in sequence [6x] - Fastener Specifications
  41. Connect all electrical connectors.
  42. GM5862841
    NOTE:

    Some components not shown for graphic clarity.

    Positive Crankcase Ventilation Foul Air Tube (2) - Install

  43. Positive Crankcase Ventilation Tube Connector (1) - Connect [2x] - Plastic Collar Quick Connect Fitting Service
  44. GM5862663
    NOTE:

    Some components not shown for graphic clarity.

    Charge Air Cooler Cover Seal (3) - Install NEW [2x]

  45. Intake Manifold Gasket (2) - Install NEW
  46. Charge Air Cooler Cover (1) - Install
  47. GM5862662
    NOTE:

    Some components not shown for graphic clarity.

    Charge Air Cooler Cover Bolt (2) - Install and hand tighten [12x]

  48. Charge Air Cooler Bolt (1) - Install and hand tighten [2x]
  49. Charge Air Cooler Bolt (1) - Tighten in sequence [14x] - Fastener Specifications
  50. Charge Air Cooler Cover Bolt - Tighten in sequence [2x] - Fastener Specifications
  51. Connect the electrical connectors.
  52. GM5840540

    Charge Air Cooler Inlet Air Tube Seal (4) - Install NEW

  53. Charge Air Cooler Inlet Pipe (3) - Install
  54. Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
  55. Charge Air Cooler Inlet Air Tube Bolt (1) - Install and tighten [2x] - Fastener Specifications
  56. GM5840576

    Charge Air Cooler Inlet Air Tube Seal (4) - Install NEW

  57. Charge Air Cooler Inlet Pipe (3) - Install
  58. Charge Air Bypass Valve Tube Connector Clamp (2) - Tighten - Fastener Specifications
  59. Charge Air Cooler Inlet Air Tube Bolt (1) - Install and tighten [2x] - Fastener Specifications
  60. GM4057738

    Turbocharger Wastegate Actuator Vacuum Tank (2) - Install

  61. Turbocharger Wastegate Actuator Vacuum Tank Bolt (1) - Install and tighten [2x] - Fastener Specifications
  62. GM4057709

    Electrical Connector (1) @ Charge Air Bypass Valve (2) - Connect

  63. GM4057618

    Charge Air Bypass Valve Tube (1) @ Charge Air Bypass Valve - Connect - Plastic Collar Quick Connect Fitting Service

  64. GM4057453

    Electrical Connector (1) @ Charge Air Bypass Valve (2) - Connect

  65. GM4057385

    Charge Air Bypass Valve Tube (1) @ Charge Air Bypass Valve - Connect - Plastic Collar Quick Connect Fitting Service

  66. GM4057362

    Turbocharger Wastegate Actuator Vacuum Source Tube (1) @ Vacuum Pump - Connect - Plastic Collar Quick Connect Fitting Service

  67. GM4052248

    Charge Air Bypass Valve Vacuum Tank Tube (3) - Connect - Plastic Collar Quick Connect Fitting Service

  68. GM5839386

    Turbocharger Wastegate Actuator Vacuum Tank Bolt (3) - Install and tighten [2x] - Fastener Specifications

  69. GM5839336

    Turbocharger Wastegate Actuator Vacuum Tank Bolt (3) - Install and tighten [2x] - Fastener Specifications

  70. Connect the electrical connectors.
  71. GM5842421

    Evaporative Emission Canister Purge Tube (1) - Install

  72. Evaporative Emission Canister Purge Tube (1) - Connect [2x] - Plastic Collar Quick Connect Fitting Service
  73. GM5880449

    Turbocharger Gasket (2) - Install NEW

  74. Compressor Air Intake Turbocharger (1) - Remove
  75. GM5880448

    Turbocharger Bolt (1) - Install and tighten in sequence [4x] - Fastener Specifications

  76. GM5892103

    Turbocharger Coolant Feed Pipe (3) @ Compressor Air Intake Turbocharger - Install

  77. Turbocharger Coolant Feed and Return Pipe Gasket (2) - Install NEW [2x]
  78. Turbocharger Coolant Feed and Return Pipe Bolt (1) - Install and tighten - Fastener Specifications
  79. GM5875520
    NOTE:

    Some components not shown for graphic clarity.

    Turbocharger Oil Return Pipe Gasket (2) - Install NEW [2x]

  80. Turbocharger Oil Return Pipe (1) - Install
  81. GM5875517
    NOTE:

    Some components not shown for graphic clarity.

    Turbocharger Oil Return Pipe Bolt (1) - Install and tighten [4x] - Fastener Specifications

  82. GM5875574
    NOTE:

    Some components not shown for graphic clarity.

    Turbocharger Oil Feed Pipe (4) - Install

  83. Turbocharger Oil Feed Pipe Washer (3) - Install NEW [2x]
  84. Turbocharger Oil Feed Pipe Bolt (2) - Install and tighten - Fastener Specifications
  85. Turbocharger Oil Feed Pipe Fitting Clip (1) - Install
  86. GM5873812

    Turbocharger Coolant Return Pipe (3) - Install

  87. Turbocharger Coolant Feed and Return Pipe Gasket (2) - Install NEW [2x]
  88. Turbocharger Coolant Feed and Return Pipe Bolt (1) - Install and tighten - Fastener Specifications
  89. GM5873832

    Retaining Clip (1) - Install

  90. GM5876059

    Turbocharger Heat Shield (1) - Install

  91. GM5873866

    Turbocharger Heat Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications

  92. GM5869549
    NOTE:

    Some components not shown for graphic clarity.

    Engine Mount Bracket (1) - Install

  93. GM5869547
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

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

  94. Engine Mount Engine Side Bolt- Left Side (1) - Install and hand tighten [4x]
  95. Engine Mount Engine Side Bolt- Left Side (1) - Tighten [4x] - Fastener Specifications
  96. GM5869862
    NOTE:

    Some components not shown for graphic clarity.

    Engine Mount Bracket (1) - Install

  97. GM5869860
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

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

  98. GM4017620

    Install the EN-46106  Flywheel Holding Tool (1).

  99. GM5906799
    NOTE:

    The automatic transmission flex plate does not use a locating pin for alignment and will not initially seat against the crankshaft flange, but will be pulled onto the crankshaft by the automatic transmission flex plate bolts. This procedure requires a 3 stage tightening process.

    Automatic Transmission Flex Plate (2) - Install

  100. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
    101. CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

  101. Automatic Transmission Flex Plate Bolt (1) - Install NEW and hand tighten [8x]
  102. Automatic Transmission Flex Plate Bolt (1) - Tighten in sequence [8x] - Fastener Specifications
  103. GM4017620

    Remove the EN-46106  Flywheel Holding Tool (1).

  104. Install a suitable chain to the two engine lift brackets to support the engine.
  105. Using a suitable engine lifting device, remove the engine from the engine stand. Engine Removal and Installation (with MHU) , or Engine Removal and Installation (with MG9) 
    106. NOTE:

    Prelube is necessary if the engine is replaced or overhauled.

  106. If the engine is replaced with a new engine or has been overhauled, perform the engine prelubing procedure. Engine Prelubing 
  107. Disable the ignition system.
  108. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
  109. Enable the ignition system.
  110. Start the engine and listen for unusual noises.
  111. Check the vehicle oil pressure gauge and confirm that the engine has acceptable oil pressure.

    If necessary, install an oil pressure gauge and measure the engine oil pressure.

  112. Start the engine and run the engine speed at about 1, 000 RPM until the engine has reached normal operating temperature.
  113. Listen for sticking lifters and other unusual noises.
  114. Inspect for fuel, oil, and/or other coolant leaks while the engine is running.
  115. Perform a final inspection for the proper engine oil and coolant levels.
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