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Installation Procedure

WARNING: This page is about a different variant/trim than selected.
CAUTION:

Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

NOTE:
  • Do not use the cylinder head bolts again. Install NEW cylinder head bolts during assembly.
  • Do not use any type of sealant on the cylinder head gasket, unless specified.
  • The cylinder head gaskets must be installed in the proper direction and position.
    Fig 1: Deflectors
    GM4629170Courtesy of GENERAL MOTORS COMPANY
  1. Check that the 2 deflectors (1) are installed in the engine block and install 2 NEW deflectors if the deflectors are missing.
    2. NOTE:

    Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material.

  2. Clean all sealing surfaces.
  3. Inspect the flatness of the cylinder head and cylinder block sealing surfaces.
  4. Assemble Cylinder Head. Refer to Cylinder Head Assemble .
    5. Fig 2: Indicator
    GM3351979Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    For the measurement, the piston has to stay on TDC. Measure the piston projection dimensions at all pistons.

  5. Install the GE-7872  indicator (1).
  6. Measure the piston projection of the cylinder 1 and the cylinder 4.
    7. Fig 3: Crankshaft Fixing Tool And Bolts
    GM4421988Courtesy of GENERAL MOTORS COMPANY
  7. Remove Bolts (3) (Qty: 2)
  8. Remove the EN-51140  fixing tool (2).
    9. Fig 4: Crankshaft Pulley Bolts
    GM4421989Courtesy of GENERAL MOTORS COMPANY
  9. Install Crankshaft Pulley Bolts (1) (Qty: 4)
    10. Fig 5: Timing Chain And Suitable Tool
    GM4421990Courtesy of GENERAL MOTORS COMPANY
  10. Hold the timing chain (1) up with a suitable tool like an extension (2).
    11. NOTE:

    A second technician is required.

  11. Rotate the crankshaft 180 degrees, use a pry bar at the 4 crankshaft pulley bolts.
  12. Measure the piston projection of the cylinder 2 and the cylinder 3.
  13. Rotate the crankshaft 180 degrees
    14. Fig 6: Crankshaft Pulley Bolts
    GM4421989Courtesy of GENERAL MOTORS COMPANY
  14. Remove Crankshaft Pulley Bolts (1) (Qty: 4)
    15. Fig 7: Crankshaft Fixing Tool And Bolts
    GM4421988Courtesy of GENERAL MOTORS COMPANY
  15. Install the EN-51140  fixing tool (2).
  16. Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
    17. Fig 8: Cylinder Head Gasket Identification Marks
    GM4421991Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The largest piston projection is decisive for the selection of the cylinder head gasket with the corresponding marking. The different between the three max. projection measurements must be no greater than 0.1 mm (0.0039 in).

  17. Select the cylinder head gasket with the correct identification marks (1):
    1. Piston projection 0.440 - 0.535 mm (0.0173 - 0.0211 in), choose cylinder head gasket with identification mark on Position I, thickness 1.25 mm (0.049 in).
    2. Piston projection 0.535 - 0.630 mm (0.0211 - 0.0248 in), choose cylinder head gasket with identification mark on Position II, thickness 1.35 mm (0.053 in).
    3. Piston projection 0.630 - 0.725 mm (0.0248 - 0.0285 in), choose cylinder head gasket with identification mark on Position III, thickness 1.45 mm (0.057 in).
    18. Fig 9: Cylinder Head, Bolts, Gasket And Guide Sleeves
    GM4421986Courtesy of GENERAL MOTORS COMPANY
  18. Install NEW Cylinder Head Gasket (3)
  19. Install Cylinder Head (2)
  20. Install NEW Cylinder Head Bolts (1) (Qty: 10) - Do NOT tighten.
    21. Fig 10: Cylinder Head Bolt Tightening Sequence
    GM4421993Courtesy of GENERAL MOTORS COMPANY
  21. Tighten Cylinder Head Bolts in sequence
      CAUTION:

      Refer to Fastener Caution

      CAUTION:

      Refer to Torque-to-Yield Fastener Caution

    1. First Pass: 50 N.m (37 lb ft)
    2. Second Pass: 90 degrees - Use the special tool: EN-45059  angle meter
    3. Third Pass: 90 degrees - Use the special tool: EN-45059  angle meter
    4. Final Pass: 90 degrees - Use the special tool: EN-45059  angle meter
    22. Fig 11: Outer Cylinder Head Bolts
    GM4421984Courtesy of GENERAL MOTORS COMPANY
  22. Install the NEW 2 cylinder head outer bolts (1) and tighten in 2 passes:
      CAUTION:

      Refer to Torque-to-Yield Fastener Caution

    1. First Pass: 20 N.m (15 lb ft)
    2. Final Pass: 45 degrees - Use the special tool: EN-45059  angle meter
    23. Fig 12: Engine Mount Bracket Bolts
    GM4421983Courtesy of GENERAL MOTORS COMPANY
  23. Install and tighten Engine Mount Bracket Bolts (1) (Qty: 2) to 62 N.m (46 lb ft)
    24. Fig 13: Upper Timing Chain Upper Guide And Bolts
    GM4421982Courtesy of GENERAL MOTORS COMPANY
  24. Re-cut thread at cylinder head for the upper timing chain upper guide bolt (2).
    25. NOTE:

    The tightening procedure of the timing chain upper guide bolts should be completed within 10 minutes.

  25. Apply thread lock agent to the upper timing chain upper guide bolt (2).
  26. Install the upper timing chain upper guide bolt (2) and tighten to 11 N.m (97 lb in).
  27. Remove the lower timing chain upper guide bolt (3).
  28. Re-cut thread at engine block for the lower timing chain upper guide bolt (3).
  29. Apply thread lock agent to the lower timing chain upper guide bolt.
  30. Install and tighten the lower timing chain upper guide bolt (3) to 11 N.m (97 lb in).
    31. Fig 14: Valve Lifter Roller Assemblies
    GM4421981Courtesy of GENERAL MOTORS COMPANY
  31. Coat the 16 valve lifter with engine oil.
  32. Install the 16 valve lifter with valve lifter roller (1) in the order as they was removed.
    33. Fig 15: Bearing Bracket
    GM4421980Courtesy of GENERAL MOTORS COMPANY
  33. Install the bearing bracket (1).
    34. Fig 16: Exhaust Camshaft With Bore Of Camshaft Sprocket Upwards
    GM4421979Courtesy of GENERAL MOTORS COMPANY
  34. Coat all bearing surfaces with engine oil.
  35. Install the exhaust camshaft (1), ensure the bore (2) of the camshaft sprocket shows upwards.
    36. Fig 17: Exhaust Camshaft Bearing Caps And Bolts
    GM4421978Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Note the arrows as marks on the camshaft bearing caps, which shows on the outside of the cylinder head.

  36. Install the exhaust camshaft bearing caps (2) in the order as they was removed.
  37. Install the 8 exhaust camshaft bearing cap bolts (1).
    38. Fig 18: Exhaust Camshaft Bearing Cap Bolt Tightening Sequence
    GM4421994Courtesy of GENERAL MOTORS COMPANY
  38. Tighten the 8 exhaust camshaft bearing cap bolts in sequence as shown to 10 N.m (89 lb in).
    39. Fig 19: Intake Camshaft With Camshaft Sprocket Marks Aligned
    GM4421996Courtesy of GENERAL MOTORS COMPANY
  39. Coat all bearing surfaces with engine oil.
    40. NOTE:

    Ensure the marks (2) of the camshaft sprocket are aligned.

  40. Install Intake Camshaft (1)
    41. Fig 20: Mark Exhaust Camshaft Sprocket And Intake Camshaft Sprocket With Paint Marks
    GM4421972Courtesy of GENERAL MOTORS COMPANY
  41. Check the marks (1) of the camshaft sprockets whether they are aligned.
    42. Fig 21: Intake Camshaft Bearing Caps And Bolts
    GM4421975Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Note the arrows as marks on the camshaft bearing caps, which shows on the outside of the cylinder head.

  42. Install the 4 intake camshaft bearing caps (2) in the order as they was removed.
  43. Install the 8 intake camshaft bearing cap bolts (1).
    44. Fig 22: Intake Camshaft Bearing Cap Bolt Tightening Sequence
    GM4421995Courtesy of GENERAL MOTORS COMPANY
  44. Tighten the 8 intake camshaft bearing cap bolts in sequence as shown to 10 N.m (89 lb in).
    45. Fig 23: Split Intake Camshaft Sprocket Fixing Tool
    GM4421973Courtesy of GENERAL MOTORS COMPANY
  45. Remove the EN-50509  fixing tool (1).
    46. Fig 24: Camshaft Bearing Rear Cap And Bolts
    GM4421971Courtesy of GENERAL MOTORS COMPANY
  46. Coat all bearing surfaces with engine oil.
  47. Install Camshaft Bearing Rear Cap (2)
  48. Install the 4 camshaft bearing rear cap bolts (1).
    49. Fig 25: Camshaft Rear Cap Bolt Tightening Sequence
    GM4421992Courtesy of GENERAL MOTORS COMPANY
  49. Tighten the 4 camshaft rear cap bolts in sequence as shown to 25 N.m (18 lb ft).
    50. Fig 26: Camshaft Sprocket Fixing Tool
    GM4421970Courtesy of GENERAL MOTORS COMPANY
  50. Install the EN-51143  fixing tool (1), by carefully turning the hexagon of the camshaft.
    51. Fig 27: Fuel Injection Fuel Rail And Bolts
    GM4537931Courtesy of GENERAL MOTORS COMPANY
  51. Install Fuel Injection Fuel Rail (2)
  52. Install and tighten Fuel Injection Fuel Rail Bolts (1) (Qty: 2) to 25 N.m (18 lb ft)
  53. Install Glow Plugs (Qty: 4). Refer to Glow Plug Replacement
  54. Install Camshaft Sprocket. Refer to Camshaft Sprocket Replacement 
  55. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (LH7)
  56. Install the intake manifold. Refer to Intake Manifold Replacement 
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