Check Crankshaft Bearing Clearance (with Plastigage)

1. Clean all sealant surfaces from engine block.
2. NOTE:

   • Ensure that guide lugs (1) are properly seated.
   • If the old crankshaft bearing was reused, set it in as removed.

   Crankshaft Upper Bearing (2) - Install [5x]

3. NOTE:

   Do NOT rotate the crankshaft.

   Lay on 5 times plastigage (flexible plastic thread) axially over the entire width of the crankshaft bearing journal (1).

4. NOTE:

   If the old crankshaft bearing was reused, set it in as removed.

   Install the 2 crankshaft thrust bearings (1).

5. Crankshaft (1) - Install

6. Check the 2 crankshaft thrust bearings (1) for proper seat.

7. NOTE:

   • Ensure that guide lugs (1) are properly seated.
   • If the old crankshaft bearing was reused, set it in as removed.

   Crankshaft Lower Bearing (2) - Install [5x]

8. NOTE:

   Set it in as removed.

   Crankshaft Bearing Cap (2) - Install [5x]

9. Crankshaft Bearing Cap Bolt (1) - Install NEW [10x]
10. Fig 1: Crankshaft Bearing Cap Bolts Tightening Sequence

    Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Fastener Caution .

    CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

    Tighten the 5 crankshaft bearing cap bolts in sequence using EN-45059  Angle Meter. Fastener Specifications

11. NOTE:

    Lay aside in order removed.

    Crankshaft Bearing Cap Bolt (1) - Remove and DISCARD [10x]

12. Crankshaft Bearing Cap (2) - Remove [5x]
13. NOTE:

    • Mind the guide lug (1) for the installations procedure.
    • Mark the installation position of the crankshaft lower bearing. Lay aside in order removed.

    Crankshaft Lower Bearing (2) - Remove [5x]

14. NOTE:

    When reading the value, do NOT confuse millimeters and inches on the measuring scale.

    Measure the crankshaft bearing play.

    • Compare the width of the flattened plastic thread (1) to the measuring scale (2).
    • For the permissible crankshaft bearing clearance, refer to Engine Mechanical Specifications .
15. NOTE:

    Mark the installation position of the crankshaft upper bearings and the thrust bearings. Lay aside in order removed.

    Crankshaft (1) - Remove

16. Crankshaft Upper Bearing (3) - Remove [5x]
17. Remove the 2 crankshaft thrust bearings (2).

Installation Procedure

1. NOTE:

   • Ensure that guide lugs (1) are properly seated.
   • If the old crankshaft bearing was reused, set it in as removed.

   Crankshaft Upper Bearing (2) - Install [5x]

   1. For the selection of the right bearing measure the crankshaft bearing journals. Crankshaft and Bearing Removal and Installation 
   2. Also measure the bearing bore diameter in cylinder block. Engine Block Overhaul 
   3. For the selection of the right see the selection of crankshaft bearing table. Crankshaft and Bearing Removal and Installation 
2. NOTE:

   If the old crankshaft bearing was reused, set it in as removed.

   Install the 2 crankshaft thrust bearings (1).

3. Crankshaft (1) - Install

4. Check the 2 crankshaft thrust bearings (1) for proper seat.

5. NOTE:

   • Ensure that guide lugs (1) are properly seated.
   • If the old crankshaft bearing was reused, set it in as removed.

   Crankshaft Lower Bearing (2) - Install [5x]

6. NOTE:

   Set it in as removed.

   Crankshaft Bearing Cap (2) - Install [5x]

7. Crankshaft Bearing Cap Bolt (1) - Install NEW and tighten in sequence [10x] with a EN-45059  Angle Meter. Fastener Specifications
8. Coat the following components with engine oil:
   • Pistons
   • Connecting rods
   • Cylinder bores
   • Connecting rod bearings
9. Install the 8 connecting rod bearings to the connecting rod bearing caps and the connecting rods.

10. The arrow on the top of the pistons (1) must point to the timing side.

11. NOTE:

    • If the old piston and connecting rod will be reused, install to their original position.
    • The arrow on the top of the piston and the marks of the piston and connecting rod, must point to the timing side.
    • The mark (1) must point to the engine intake side.

    Install a piston ring compressor in order to compress the piston rings.

12. Install the 2 pistons (2) and the 2 connecting rods along (4) with the connecting rod upper bearing to the cylinder 1 and the cylinder 4, using EN-51454  Connecting Rod Guides (3).
13. NOTE:

    • If the old connecting rod bearing caps will be reused, install in their original position.
    • The mark (4) must point to the engine intake side.

    Install the 2 connecting rod bearing caps (2) along with the 2 connecting rod lower bearings (1) to the cylinder 1 and the cylinder 4.

CAUTION:

Refer to Fastener Caution .

CAUTION:

Refer to Torque-to-Yield Fastener Caution .

14. Install 4 NEW connecting rod bolts (3) and tighten in two passes. Fastener Specifications
15. Turn the crankshaft 180 degrees.
16. NOTE:

    • If the old piston and connecting rod will be reused, install to their original position.
    • The arrow on the top of the piston and the marks of the piston and connecting rod, must point to the timing side.
    • The mark (1) must point to the engine intake side.

    Install a piston ring compressor in order to compress the piston rings.

17. Install the 2 pistons (2) and the 2 connecting rods along with the connecting rod upper bearing (4) to the cylinder 2 and the cylinder 3, using EN-51454  Connecting Rod Guides (3).
18. NOTE:

    • If the old connecting rod bearing caps will be reused, install to their original position.
    • The mark (3) must point to the engine intake side.

    Install the 2 connecting rod bearing caps (2) along with the 2 connecting rod lower bearings (1) to the cylinder 2 and the cylinder 3.

19. Install 4 NEW connecting rod bolts (4) and tighten in two passes. Fastener Specifications
20. Clean all sealing surfaces.
21. NOTE:

    • The engine block surface must be free of contamination prior to applying the sealer.
    • Install and align the engine block lower structural extension to the block within 10 minutes of applying the sealer.
    • The oil pan must be fastened to final torque specification within 60 minutes of applying the sealer.

    Apply approximately a 4 mm (0.16 in) thick bead of sealant (2, 3) to the engine block lower structural extension. Finally apply a 12 mm  dab of sealant at the locations indicated (1). Adhesives, Fluids, Lubricants, and Sealers

22. Engine Block Lower Structural Extension (1) - Install

23. NOTE:

    Take note that there are different bolt lengths.

    Engine Block Lower Structural Extension Inner Bolts (1, 2, 3) - Install and hand tighten [3x]

24. NOTE:

    Take note that there are different bolt lengths.

    Engine Block Lower Structural Extension Outer Bolts (1, 2, 3, 4, 5) - Install and hand tighten [15x]

25. Fig 2: Engine Block Lower Structural Extension Tightening Sequence

    Courtesy of GENERAL MOTORS COMPANY

    Engine Block Lower Structural Extension Bolt - Tighten in sequence [18x] - Fastener Specifications

26. Rotate the balance shaft (1) approximately 52 degreesin the direction of the arrow.

27. Hold the balance shaft in that position.

28. Install the EN-52441  Balance Shaft Timing Tool (1) through the hole in the oil pump.

29. Balance Chain (1) @ Balance Shaft Sprocket (2) - Install - Align the white link marked on the balance chain (4) with the balance shaft sprocket mark (3).

30. Balance Chain (5) @ Crankshaft - Install - Align the blue link marked on the balance chain (2) with the mark at the crankshaft (1).

31. Install the balance shaft sprocket (3) along with the balance chain (5) with the adjusted position to the balance shaft.
NOTE:

Hold on the balance shaft sprocket (3) with a suitable wrench to tighten the balance shaft sprocket bolt (4).

32. Balance Shaft Sprocket Bolt (4) - Install NEW and tighten - Fastener Specifications

33. Balancer Chain Guide (2) - Install

34. Balance Chain Guide Bolt (1) - Install and tighten [2x] - Fastener Specifications

35. Balancer Chain Tensioner (1) - Install

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

37. Remove the EN-955-A  Locking Pin (2) from the balance chain tensioner (1).

38. Remove the EN-52441  Balance Shaft Timing Tool (1).

39. Install the EN-52441  Balance Shaft Timing Tool (1) through the hole in the oil pump.

40. If the EN-52441  Balance Shaft Timing Tool (1) fits in the hole of the oil pump, the balance shafts are properly adjusted.
41. If the EN-52441  Balance Shaft Timing Tool (1) does not fit in the hole of the oil pump, repeat the steps to adjust the balance shafts and the balance chain again.
42. Remove the EN-52441  Balance Shaft Timing Tool (1).
43. Clean all sealing surfaces.

44. Slip the EN-52439 - 3  Crankshaft Oil Seal Ring Guide Rear (2) through the seal from the outside cover to inside 2 times to shape the seal lip in the crankshaft rear oil seal housing (1).

45. Mark the crankshaft rear oil seal housing with a reference line to the dowel to align the EN-52439 - 1  Crankshaft Oil Seal Ring Guide Rear.

46. Install the EN-52439 - 3  Crankshaft Oil Seal Ring Guide Rear (2) through the seal with the EN-52439 - 1  Crankshaft Oil Seal Ring Guide Rear (1) to keep the shape of the seal in the crankshaft rear oil seal housing (3).

47. Align the EN-52439 - 1  Crankshaft Oil Seal Ring Guide Rear dowel hole to the line previous applied on the new cover.
48. NOTE:

    • The crankshaft rear oil seal housing surface must be free of contamination prior to applying the sealer.
    • Install and align the crankshaft rear oil seal housing to the block within 10 minutes after applying the sealer.
    • The crankshaft rear oil seal housing must be fastened to final torque specification within 15 minutes after applying the sealer.

    Set the crankshaft rear oil seal housing on the EN-52439 - 1  Crankshaft Oil Seal Ring Guide Rear (2) to apply approximately a 4 mm (0.16 in) thick bead of sealant (1) to the crankshaft rear oil seal housing. Adhesives, Fluids, Lubricants, and Sealers

49. EN-52483  Guide Pins (2) - Install

50. Crankshaft Rear Oil Seal Housing (1) - Install NEW
51. EN-52439 - 1  Crankshaft Oil Seal Ring Guide Rear (3).

52. Crankshaft Rear Oil Seal Housing Bolt (1) - Install and hand tighten [13x]

53. Remove the EN-52483  Guide Pins
54. Fig 3: Crankshaft Rear Oil Seal Housing Tightening Sequence

    Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The bolts (1, 2, 3, 5) must be tightening two times.

    Crankshaft Rear Oil Seal Housing Bolt - Tighten in sequence [13x] - Fastener Specifications

55. Clean all sealing surfaces.
56. Spray Low LOC brake cleaner on the LCE sealing surface and wipe off with a clean shop towel. Avoided touching the surface after cleaning and air dry with shop air.
57. Wipe the oil pan surface with the Adhesion Plastic Pan Primer Promoter with a clean shop towel. Allow the cleaner to flash / evaporate. Wipe off the sealing surfaces with a lint free cloth. Do not touch the sealing surface after cleaning to avoid inducing containment debris to the bonding surface area. Adhesives, Fluids, Lubricants, and Sealers

58. Apply approximately a 4 mm (0.16 in) thick bead of sealant (1) to the lower oil pan. Adhesives, Fluids, Lubricants, and Sealers

59. Install EN-52483  Guide Pin in two locations to keep oil pan square.
60. NOTE:

    • The engine block lower structural extension surface must be free of contamination prior to applying the sealer.
    • Install and align the oil pan to the block within 10 minutes after applying the sealer.
    • The oil pan must be fastened to final torque specification within 15 minutes after applying the sealer.
    • Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

    Lower Oil Pan (1) - Install

61. Fig 4: Lower Oil Pan Bolts Tightening Sequence

    Courtesy of GENERAL MOTORS COMPANY

    Lower Oil Pan Bolt (1) - Install and hand tighten [18x]

62. Lower Oil Pan Bolt (1) - Tighten in sequence [18x] - Fastener Specifications
63. NOTE:

    • Check that the Locating Pin (2) sits correct in the crankshaft.
    • Check that the Locating Pin (2) sits in the proper hole from the crankshaft position sensor inner excitor ring.
    CAUTION:

    Do not allow the crankshaft position sensor reluctor ring to come into contact with external magnetic fields or sharp metal objects. Do not drop the crankshaft position sensor reluctor ring. Do not damage the rubberized encoder track. Failure to follow these precautions may cause damage to the component.

    Crankshaft Position Sensor Inner Exciter Ring (1) - Install

64. Clean the 8 crankshaft threads.
65. NOTE:

    • Check the flex plate for damage before installation.
    • Check the flex plate locating pin for correct seat in the crankshaft.

    Automatic Transmission Flex Plate (1) - Install

66. Check that flex plate locating pin (2) is in the right hole of the automatic transmission flex plate.
67. The flex plate locating pin (2) depth should be 5 mm (a)
68. Automatic Transmission Flex Plate Bolt (3) - Install NEW and hand tighten [8x]
69. 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 timing pin must be placed in the retracted position using the handle (1) and twisting to locked position. The slide part (4) to be installed to the flexplate when torque is applied to the flexplate or crankshaft balancer bolt.

    Install the slide (4) from the EN-52476  Flywheel Lock and Alignment Tool (1) to the automatic transmission flexplate.

70. Automatic Transmission Flex Plate Bolt (2) - Tighten [8x] - Fastener Specifications

71. Crankshaft Position Sensor (1) - Install

72. Crankshaft Position Sensor Bolt (2) - Install and tighten - Fastener Specifications
73. Flip engine over on stand.
74. NOTE:

    Check that the 2 guide pins are seated correctly in the cylinder head.

    Cylinder Head Gasket (3) - Install NEW

75. Cylinder Head (2) - Install
76. Cylinder Head Bolt (1) - Install NEW and hand tighten-(M8) [10x]
77. NOTE:

    Ensure the correct bolt length is used in the correct location.

    Cylinder Head Bolt (1, 2, 3) - Install and hand tighten-(M6) [8x]

78. Cylinder Head Bolt - [18x] Tighten - Fastener Specifications

79. Install a NEW turbocharger oil return pipe seal (6).

80. Install a NEW turbocharger oil feed pipe gasket (7).
81. Install a NEW the turbocharger heat shield (1).
82. Install the compressor air intake turbocharger (3).
83. Install 4 NEW turbocharger bolt (2) and tighten. Fastener Specifications
84. Install the 2 oil feed pipe bolts (4) and tighten. Fastener Specifications
85. Install the oil feed pipe bolt (5) and tighten. Fastener Specifications
86. Clean all sealing surfaces.

87. EN-46109  Guide Pins - Install

NOTE:

A small amount of adhesive in the corners will help keep the gasket in place.

88. Camshaft Cover Gasket (2) - Install NEW
89. Camshaft Carrier (1) - Install
90. EN-46109  Guide Pins - Remove

91. Camshaft Cover Stud (1) - Install and tighten in sequence [14x] - Fastener Specifications

92. Camshaft Carrier Bolt (2) - Install and tighten in sequence-M6 [4x] - Fastener Specifications
93. Camshaft Carrier Bolt (3) - Install and tighten in sequence-M8 [4x] - Fastener Specifications

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

95. Turbocharger Coolant Feed and Return Pipe (1) - Install

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

97. Turbocharger Coolant Return Hose Clamp (2) - Engage [2x]

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

99. Electrical Connector (1) @ Turbocharger Wastegate Actuator - Connect

100. Engine Wiring Harness Retainer (2) @ Turbocharger Coolant Feed and Return Pipe - Install [2x]

101. Electrical Connector (1) @ Turbocharger Bypass Valve Solenoid (2) - Connect

102. Engine Wiring Harness Bracket (3) - Install

103. Engine Wiring Harness Conduit Nut (2) - Install and tighten - Fastener Specifications
104. Engine Wiring Harness Conduit Bracket Bolt (1) - Install and tighten - Fastener Specifications

105. Engine Wiring Harness (2) - Reposition

106. Retainer (1) - Install [5x]

107. Radiator Surge Tank Inlet Pipe Bracket - Install [2x]

108. Radiator Surge Tank Outlet Hose Clip Bracket Nut [2x] - Install and tighten [2x] - Fastener Specifications
109. Install harness retainers as needed.
110. To set the NEW timing chain tensioner follow next steps if needed.

111. Remove the timing chain tensioner plunger (1) from the timing chain tensioner body (2).

112. NOTE:

     The ratchet mechanism will lock into place when inward pressure is released after it is turned clockwise until it is fully retracted.

     Use the J-45027-1  Tensioner Tool Handle (1) to press the ratchet mechanism of the timing chain tensioner plunger (2) inward while rotating it clockwise.

NOTE:

If the ratchet mechanism does not lock into place and begins to extend outward, reapply inward pressure with clockwise rotation until the ratchet mechanism will not rotate further, then release into the locked position.

113. Release pressure on the ratchet mechanism of the timing chain plunger (2) until it locks into place.
114. Remove the J-45027-1  Tensioner Tool Handle (1).

115. Install the timing chain plunger (1) into the timing chain tensioner body (2).

116. NOTE:

     Applying pressure to the timing chain tensioner plunger assembly will unlock the tensioner, it will then fully extend if pressure is released prior to installing the EN-955-10A  Locking Pin and will need to be reset again.

     Push in and hold the timing chain tensioner plunger, insert the EN-955-10A  Locking Pin (1) into the timing chain tensioner (2), then release the timing chain tensioner plunger.

117. Clean the block thread holes with a tap before installation of timing chain tensioner.

118. Timing Chain Tensioner (2) - Install
119. Timing Chain Tensioner Bolt (1) - Install and tighten [2x] - Fastener Specifications

120. Timing Chain Tensioner Shoe (2) - Install.

NOTE:

Service may offer bolts without microencapsulated thread locking adhesive. If this is the case, clean the threads and reapply adhesive to the bolts.

121. Timing Chain Tensioner Shoe Bolt (1) - Install NEW and tighten - Fastener Specifications

122. Timing Chain Guide (2) - Install.

123. Timing Chain Guide Bolt (1) - Install and hand tighten [2x]

124. Timing Chain (1) - Install

125. Timing Chain (1) @ Crankshaft Sprocket @ Timing Chain Upper Guide (2) - Install
     NOTE:

     The colored links (2) on the timing chain are only for identification.

126. 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 timing pin must be placed in the retracted position using the handle (1) and twisting to locked position. The slide part (4) to be installed to the flex plate when torque is applied to the flexplate or crankshaft balancer bolt.

     Ensure the timing pin (3) of the EN-52476  Flywheel Holding Tool (2) is installed to the automatic transmission flex plate.

127. Install the EN-52461  Cam Phaser Torque Reaction Tool (5) along with the 2 EN-52461  Cam Phaser Torque Reaction Tool (2, 3) to the camshaft carrier.

128. Tighten the 2 bolts (1, 4) of EN-52461 - 100  Adapter Cam Phaser Torque Reaction Tool.
129. CAUTION:

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

     Hold the intake camshaft sprocket (1) with hands from underneath the EN-52461  Cam Phaser Torque Reaction Tool and install the EN-52461 - 1  Holder into the intake camshaft sprocket to hold it securely before installing the camshaft sprocket bolt.

130. Line up intake camshaft sprocket (1) with alignment marks, as you install them on chain and the housing which should of been done on removal.

131. Hold the exhaust camshaft sprocket (1) with hands from underneath the EN-52461  Cam Phaser Torque Reaction Tool and install the EN-52461 - 1  Holder into the exhaust camshaft sprocket to hold it securely before installing the camshaft sprocket bolt (1).

132. Line up exhaust camshaft sprocket (1) with alignment marks, as you install them on chain and the housing which should of been done on removal.

133. Lubricate the Camshaft Sprocket Bolts (1) with clean engine oil where indicated. Adhesives, Fluids, Lubricants, and Sealers

134. Camshaft Sprocket Bolt (1) - Install NEW and hand tighten

135. Check that the EN-52461 - 1  Holder (1) sits correctly in the hole of the intake camshaft sprocket.

136. Rotate the EN-52461 - 1  Holder (1) counter clockwise.
137. While holding the EN-52461 - 1  Holder in the clockwise position to 6 N.m (53 lb in), tighten the bolt (4) just enough to hold the EN-52461 - 1  Holder in place.
138. Intake Camshaft Sprocket Bolt (2) - Tighten - Fastener Specifications
139. Check that the EN-52461 - 1  Holder (1) sits correctly in the hole of the exhaust camshaft sprocket.
140. Rotate the EN-52461 - 1  Holder counter clockwise.
141. While holding the EN-52461 - 1  Holder in the counter clockwise position to 6 N.m (53 lb in), tighten the bolt (3) just enough to hold the EN-52461 - 1  Holder in place.
142. Exhaust Camshaft Sprocket Bolt (2) - Tighten - Fastener Specifications

143. Bolt (1, 2) - Loosen

144. Slide the 2 EN-52461 - 1  Holder (3) out of the camshaft sprockets.

145. Loosen the 2 bolts (1, 4) of EN-52461 - 100  Adapter Cam Phaser Torque Reaction Tool (5).

146. Remove the EN-52461  Cam Phaser Torque Reaction Tool (5) along with the 2 EN-52461 - 100  Adapter Cam Phaser Torque Reaction Tool (2, 3) from the engine.

147. EN-955-10A  Locking Pin (1) - Remove

148. NOTE:

     • Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
     • The engine front lower cover sealing surface must be free of contamination prior to applying the sealer.
     • Install and align the engine front lower cover to engine block within 10 minutes of applying the sealer.
     • The engine front lower cover must be fastened to final torque specification within 15 minutes of applying the sealer.

     Apply approximately a 4 mm (0.16 in) thick bead of sealant (1) to the engine front cover. Adhesives, Fluids, Lubricants, and Sealers

149. Crankshaft Balancer Bolt (1) - Remove and DISCARD

150. Install EN-52440  Crankshaft Oil Seal Ring Guide Front (2) to the crankshaft.

151. Install the engine front cover (1) backwards using the 2 tabs to size the seal.

152. Remove the engine front cover (1) after seal is sized.

153. Install - EN-52483  Guide Pins (2)
154. Engine Front Cover (1) - Install
155. Remove EN-52440  Crankshaft Oil Seal Ring Guide Front (2).

156. Engine Front Cover Bolt (1) - Install and hand tighten [9x]

157. Remove the EN-52483  Guide Pins (3).
158. Engine Front Cover Bolt (1) - Tighten in sequence [9x] - Fastener Specifications

159. Remove the EN-52462 - A  Camshaft Tool (1) by rotating the levers in direction of arrows.

160. 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 timing pin must be placed in the retracted position using the handle (1) and twisting to locked position. The slide part (4) to be installed to the flex plate when torque is applied to the flexplate or crankshaft balancer bolt.

     Retract the timing pin (3) using the handle (1) of the EN-52476  Flywheel Lock and Alignment Tool (2).

161. Ensure to engage the slide (4) of the EN-52476  Flywheel Lock and Alignment Tool (2) into the automatic transmission flexplate.

162. Crankshaft Balancer (2) - Install

163. Crankshaft Balancer Bolt (1) - Install NEW and tighten - Fastener Specifications

164. Loosen and disengage the bolt (2) from EN-52462-A  Camshaft Alignment Tool (1).

165. EN-52462-A  Camshaft Alignment Tool (1) - Remove
166. Camshaft Carrier Bolt - Install and tighten - Fastener Specifications

167. Clean and apply sealant to the camshaft cover opening plugs (1). Adhesives, Fluids, Lubricants, and Sealers

168. Camshaft Cover Opening Plug (1) - Install and tighten [2x] - Fastener Specifications
169. Camshaft Carrier Bolt (2) - Install and tighten - Fastener Specifications
170. NOTE:

     • The timing chain upper cover sealing surface must be free of contamination prior to applying the sealer.
     • Install and align the timing chain upper cover to engine block within 10 minutes of applying the sealer.
     • The timing chain upper cover must be fastened to final torque specification within 15 minutes of applying the sealer.
     • Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

     Apply approximately a 5 mm (0.2 in) thick bead of sealant (2) on both sides between the camshaft housing and the cylinder head. Adhesives, Fluids, Lubricants, and Sealers .

171. Check that the 2 Pins (1) are in the camshaft housing or in the timing chain upper cover.

172. Timing Chain Upper Cover Seal (1) - Install NEW

173. Timing Chain Upper Cover (2) - Install

174. Timing Chain Upper Cover BoltM6 (3) - Install and tighten in sequence - Fastener Specifications

175. Timing Chain Upper Cover Bolt M5 (2) - Install and tighten in sequence [11x] - Fastener Specifications

176. Camshaft Position Actuator Magnet Gasket (2) - Install NEW [2x]

177. Camshaft Position Actuator Solenoid Valve Solenoid (1, 3) - Install [2x]
178. Camshaft Position Actuator Valve Solenoid Bolt (4) - Install and tighten [4x] - Fastener Specifications

179. The EN-52443  High Pressure Fuel Pump Alignment Tool has two ends marked with number 1 (1) and number 2 (2).

180. Install the EN-52443  High Pressure Fuel Pump Alignment Tool (2) with the number 2 (1) facing outward to ensure the camshaft lobe is at the base position.

181. Remove the EN-52443  High Pressure Fuel Pump Alignment Tool (1).

182. Lubricate the valve lifter follower (2) with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

183. Valve Lifter Follower (2) - Install
184. Fuel Pump Seal (3) - Install NEW
185. Fuel Pump (1) - Install
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.

186. Fuel Pump Bolt (4) - Install and tighten [2x] - Fastener Specifications
187. Connect the fuel pump electrical connector.

188. Fuel Feed Intermediate Pipe (2) - Install NEW

189. Nut @ Fuel Feed Intermediate Pipe (2) - Tighten [2x] - Fastener Specifications
190. Fuel Injection Fuel Feed Pipe Bolt (1) - Install - Fastener Specifications
191. 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

192. Fuel Pump Cover (2) - Install

193. Fuel Pump Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications

194. Water Outlet Seal (2) - Install NEW

195. Engine Coolant Flow Control Valve (1) - Install

196. Engine Coolant Flow Control Valve Bolt (1) - Install and tighten [4x] - Fastener Specifications

197. Install a NEW intake manifold seal (1).

198. Install the intake manifold and throttle body as and assembly (2).
199. Intake Manifold Bolt (3) - Install and tighten [7x] - Fastener Specifications

200. Evaporative Emission Canister Purge Pump (2) - Install

201. Evaporative Emission Canister Purge Pump Bolt (1, 3) - Install and tighten [3x] - Fastener Specifications
202. Wiring Harness Clip (4) @ Evaporative Emission Canister Purge Pump Bracket - Clip

203. Turbocharger Oil Feed Pipe Gasket (2) - Install NEW

204. Engine Coolant Air Bleed Pipe (1) - Install

205. Engine Coolant Air Bleed Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications

206. Engine Coolant Air Bleed Pipe (2) @ Engine Coolant Flow Control Valve (3) - Install

207. Clamp (4) - Install - Hose Clamp Replacement Guidelines - Spring Type
208. Engine Coolant Air Bleed Pipe Bolt (1) - Install and tighten - Fastener Specifications

209. Engine Coolant Manifold Gasket (2) - Install NEW

210. Engine Coolant Heater Exhaust Pipe (1) - Install

211. Engine Coolant Heater Exhaust Pipe Bolt (3, 4) - Install [3x]

212. Connect the electrical connector:(1)
213. Reposition the sleeve (2).

214. Clamp (1) - Install - Hose Clamp Replacement Guidelines - Spring Type

215. Engine Coolant Heater Exhaust Pipe Bracket Bolt (2) - Install and tighten - Fastener Specifications

216. Thermostat Bypass Pipe (1) - Install

217. Thermostat Bypass Pipe Bolt (2) - Install and tighten [2x] - Fastener Specifications

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

219. Turbocharger Coolant Feed and Return Pipe (1) - Install

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

221. Turbocharger Coolant Feed Hose Clamp (2) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type

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

223. Engine Wiring Harness Retainer (2) @ Turbocharger Coolant Feed and Return Pipe - Install [2x]

224. Electrical Connector (1) @ Turbocharger Wastegate Actuator - Connect

225. Electrical Connector (1) @ Turbocharger Bypass Valve Solenoid (2) - Connect

226. Engine Wiring Harness Bracket (3) - Install

227. Engine Wiring Harness Conduit Nut (2) - Install and tighten - Fastener Specifications
228. Engine Wiring Harness Conduit Bracket Bolt (1) - Install and tighten - Fastener Specifications

229. Engine Wiring Harness (2) - Reposition

230. Retainer (1) - Clip [5x]

231. Radiator Surge Tank Inlet Pipe Bracket - Install [2x]

232. Radiator Surge Tank Outlet Hose Clip Bracket Nut - Install and tighten [2x] - Fastener Specifications
233. Connect harness retainers as needed.

234. Inspect the inside of the ignition coil boot for a thin, even coat of dielectric grease. If there is no grease present or additional grease is necessary, continue with the next step.

235. Apply a thin coating of dielectric grease to the inside of the ignition coil boot up to a depth of 15 mm (0.60 in)  from the end of the boot. Adhesives, Fluids, Lubricants, and Sealers
236. Remove any excess dielectric grease from around the end of the ignition coil boot and ensure there is not an excessive amount within the boot.
237. Ignition Coil (2) - Install [4x]
238. Ignition Coil Bolt (1) - Install and tighten [8x] - Fastener Specifications
239. Engine - Install - Engine Replacement (RWD) , or Engine Replacement (AWD)