Installation Procedure
- NOTE:
Install the timing chain around the crankshaft sprocket and hang it on the EN-52461 Camshaft Torque Reaction Tool or tie it up with wire until the camshaft position actuators are installed.
Timing Chain (1) - Install
- Compress the timing chain tensioner and install EN-52593 Locking Pin Tool.
Timing Chain Tensioner Gasket (3) - Install NEW
- Timing Chain Tensioner (2) - Install
- Timing Chain Tensioner Bolt (1) - Install and tighten [2x] - Fastener Specifications
Install the actuators (3, 4).
- Slide the barrel of the torque reaction tool (2) into the actuator (3, 4) and hold.
- Tighten the bolt (1) holding in the actuator being installed.
- NOTE:
Lubricate under the washer surface.
Lubricate the camshaft position actuator valve solenoid bolts (1) with clean engine oil where indicated. Adhesives, Fluids, Lubricants, and Sealers
Install and hand tighten the NEW camshaft position actuator valve solenoid bolts (1).
- Remove the EN-52593 Locking Pin Tool.
- 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 toward the engine on the EN-52461 Camshaft Torque Reaction Tool at points (1, 4) during any time the following two conditions are simultaneously met.
- The camshaft sprocket bolt is loosened or removed.
- The EN-52461 Camshaft Torque Reaction Tool bolts (2, 3) are loosened.
Shift the slack in the timing chain to the timing chain tensioner side.
- Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (2).
- Use a wrench to turn the EN-52461 Camshaft Torque Reaction Tool (1) counter-clockwise 6 N.m (53 lb in), then hold.
- Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (2) to lock the intake actuator securely in place.
- Remove the wrench from EN-52461 Camshaft Torque Reaction Tool (1).
- Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (3).
- Use a wrench to turn the EN-52461 Camshaft Torque Reaction Tool (4) counter-clockwise 6 N.m (53 lb in), then hold.
- Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (3) to lock the intake actuator securely in place.
- Remove the wrench from EN-52461 Camshaft Torque Reaction Tool (4).
Tighten the NEW camshaft position actuator valve solenoid bolts (1). Fastener Specifications
Loosen the EN-52461 Camshaft Torque Reaction Tool bolts (2) to un-lock the actuators.
- Disengage the tangs of the EN-52461 Camshaft Torque Reaction Tool (1) from the intake and exhaust camshaft position actuator slots.
Remove the 2 EN-52461 Camshaft Torque Reaction Tool bolts (3).
- EN-52461 Camshaft Torque Reaction Tool (1) @ EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter (2) - Remove
Remove the 2 EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter bolts (3).
- EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter (2) - Remove [2x]
- Rotate both handles (4) of the EN-52462-A Camshaft Alignment Tool towards the front of the engine.
Loosen and disengage the EN-52462-A Camshaft Alignment Tool bolt (2) from camshaft carrier.
- EN-52462-A Camshaft Alignment Tool (1) - Remove
Clean and apply sealant to the 2 camshaft cover core hole plugs (1). Adhesives, Fluids, Lubricants, and Sealers
- Camshaft Cover Core Hole Plug (1) - Install and tighten [2x] - Fastener Specifications
Engine Front Cover Locating Pin (1) - Install [2x]
- Timing Chain Upper Cover Seal (2) - Install NEW
- NOTE:
Ensure that the sealing surface is clear of oil, grease and old sealant material.
NOTE:Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
NOTE:The timing chain upper cover must be installed within 8 minutes of the RTV sealant application.
Apply room temperature vulcanizing (RTV) sealant at the seam between the camshaft housing and the cylinder head where indicated.
Timing Chain Upper Cover (3) - Install
- Timing Chain Upper Cover Bolt (4) - Install and hand tighten [9x]
- Timing Chain Upper Cover Bolt (5) - Install and hand tighten
- Timing Chain Upper Cover Bolt (4, 5) - Tighten in sequence [10x] - Fastener Specifications
Camshaft Position Actuator Magnet Gasket (3) - Install NEW [2x]
- Camshaft Position Actuator Magnet (2) - Install [2x]
- Camshaft Position Actuator Magnet Bolt (1) - Install and tighten [4x] - Fastener Specifications
Retainer (1) - Install
Positive Crankcase Ventilation Tube (4) - Connect - Plastic Collar Quick Connect Fitting Service
- Engine Wiring Harness (3) - Reposition
- Retainer (2) - Install [5x]
- Electrical Connector (1) - Connect [2x]
Engine Front Cover Locating Pin (1) - Install [2x]
- EN-52483 Cover Installation Guide Pins - Install
- NOTE:
Ensure that the sealing surface is clear of oil, grease and old sealant material.
NOTE:Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
NOTE:The engine front cover must be installed within 8 minutes of applying the RTV sealant application.
Apply a bead of room temperature vulcanizing sealant (1) as shown. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
Leave the seal protector that ships installed onto the NEW engine front cover on.
Install the engine front cover (2) until the seal protector is flush with the end of the crankshaft.
- Press the center of the engine front cover in, allowing the crankshaft to push out the seal protector.
- DISCARD the seal protector.
- Once the engine front cover is completely seated, inspect the seal around the crankshaft to ensure it has not folded over itself.
- EN-52483 Cover Installation Guide Pins - Remove
- Engine Front Cover Bolt (1) - Install and hand tighten [10x]
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Engine Front Cover Bolt (1) - Tighten in sequence [14x] - Fastener Specifications
Belt Idler Pulley (1) - Install - Fastener Specifications
- Crankshaft Balancer Bolt - Remove and DISCARD
- 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.
Set the timing pin feature in the retracted position from the engaged position by pulling back and twisting the handle (1) 90 degrees.
- Engage the EN-52476 Flywheel Holding Tool (2) to the flex plate.
Crankshaft Balancer (2) - Install
- Crankshaft Balancer Bolt - Install NEW and tighten - Fastener Specifications
EN-52476 Flywheel Holding Tool (2) - Remove
Auxiliary Generator Battery Jumper Cable (2) - Install
- Battery Positive Cable Nut (1) @ Starter Solenoid - Install and tighten - Fastener Specifications
- Electrical Connector (4) - Connect
- Starter (3) - Install
Starter Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Starter Stud (1) - Install and tighten - Fastener Specifications
Auxiliary Generator Battery Jumper Cable - Install
- Install and tighten the auxiliary generator battery jumper cable terminal nut (1). Fastener Specifications
- Retainer (3) - Engage
Engine Oil Cooler Seal (2) - Install NEW [2x]
- Engine Oil Cooler (1) - Install
Engine Oil Cooler Bolt (1) - Install and tighten [4x] - Fastener Specifications
Engine Oil Cooler Coolant Inlet Hose (3) @ Engine Oil Cooler - Install
- Engine Oil Cooler Coolant Outlet Hose (2) @ Engine Oil Cooler - Install
- Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Lower the vehicle.
Drive Belt Tensioner (4) - Install
- Drive Belt Tensioner Bolt (3) - Install and tighten [2x] - Fastener Specifications
- Belt Idler Pulley (2) - Install
- Belt Idler Pulley Bolt (1) - Install and tighten - Fastener Specifications
Belt Idler Pulley (1) - Install - Fastener Specifications
-
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Position the accessory drive primary belt onto all of the pulleys except one idler pulley.
- Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise and hold.
- Accessory Drive Primary Belt (2) - Install
- Release the drive belt tensioner, inspect the accessory drive primary belt (2) to ensure it is centered on all pulleys.
- NOTE:
Ensure the intake manifold cover insulator retainers fully engage the intake manifold cover studs.
Intake Manifold Cover Insulator (1) - Install
Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Install
Push down on the front of the intake manifold cover (2).
- Intake Manifold Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Install the oil fill cap.
- Fill the engine oil to the proper level with NEW engine oil. Engine Oil and Oil Filter Replacement
- Fill the cooling system. Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716)
- Connect the negative battery cable. Battery Negative Cable Disconnection and Connection
Refer to Fastener Caution .
Ensure the torque reaction tool bolt (1) is tight enough that the barrel (2) will not slip.