Installation Procedure
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.
- 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.
Check that the 2 deflectors (1) are installed in the engine block and install 2 NEW deflectors if the deflectors are missing.
- Clean all sealing surfaces.
- Inspect the flatness of the cylinder head and cylinder block sealing surfaces.
- Cylinder Head - Assemble - Cylinder Head Assemble .
- NOTE:
For the measurement, the piston has to stay on TDC. Measure the piston projection dimensions at all pistons.
Install the GE-7872 indicator (1).
- Measure the piston projection of the cylinder 1 and the cylinder 4.
Bolt (3) - Remove [2x]
- Remove the EN-51140 fixing tool (2).
Crankshaft Pulley Bolt (1) - Install [4x]
Hold the timing chain (1) up with a suitable tool like an extension (2).
- Rotate the crankshaft 180 degrees, use a pry bar at the 4 crankshaft pulley bolts.
Crankshaft Pulley Bolt (1) - Remove [4x]
Install the EN-51140 fixing tool (2).
- Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
- Measure the piston projection of the cylinder 2 and the cylinder 3.
Bolt (3) - Remove [2x]
- Remove the EN-51140 fixing tool (2).
- Rotate the crankshaft 180 degrees
Crankshaft Pulley Bolt (1) - Remove [4x]
Install the EN-51140 fixing tool (2).
- Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
- 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).
Select the cylinder head gasket with the correct identification marks (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).
- 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).
- 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).
Cylinder Head Gasket (3) - Install NEW
- Cylinder Head (2) - Install
- Cylinder Head Bolt (1) - Install NEW [10x] - Do NOT tighten.
-
Cylinder Head Bolt - Tighten in sequence
- First Pass: 50 N.m (37 lb ft)
- Second Pass: 90 degrees - Use the special tool: EN-45059 angle meter
- Third Pass: 90 degrees - Use the special tool: EN-45059 angle meter
- Final Pass: 90 degrees - Use the special tool: EN-45059 angle meter
CAUTION:CAUTION: Install the NEW 2 cylinder head outer bolts (1) and tighten in 2 passes:
- First Pass: 20 N.m (15 lb ft)
- Final Pass: 45 degrees - Use the special tool: EN-45059 angle meter
CAUTION:Install the 2 engine mount bracket bolts (1) and tighten in 2 passes:
- First Pass: 58 N.m (43 lb ft)
- Final Pass: 60-75 degrees - Use the special tool: EN-45059 angle meter
CAUTION:Re-cut thread at cylinder head for the upper timing chain upper guide bolt (2).
- Apply thread lock agent to the upper timing chain upper guide bolt (2).
- Install the upper timing chain upper guide bolt (2) and tighten to 11 N.m (97 lb in).
- Remove the lower timing chain upper guide bolt (3).
- Re-cut thread at engine block for the lower timing chain upper guide bolt (3).
- Apply thread lock agent to the lower timing chain upper guide bolt.
- Install and tighten the lower timing chain upper guide bolt (3) to 11 N.m (97 lb in).
Coat the 16 valve lifter with engine oil.
- Install the 16 valve lifter with valve lifter roller (1) in the order as they was removed.
Install the bearing bracket (1).
Coat all bearing surfaces with engine oil.
- Install the exhaust camshaft (1), ensure the bore (2) of the camshaft sprocket shows upwards.
- NOTE:
Note the arrows as marks on the camshaft bearing caps, which shows on the outside of the cylinder head.
Install the exhaust camshaft bearing caps (2) in the order as they was removed.
- Install the 8 exhaust camshaft bearing cap bolts (1).
-
Courtesy of GENERAL MOTORS COMPANY
Tighten the 8 exhaust camshaft bearing cap bolts in sequence as shown to 10 N.m (89 lb in).
Coat all bearing surfaces with engine oil.
- Intake Camshaft (1) - Install
Check the marks (1) of the camshaft sprockets whether they are aligned.
- NOTE:
Note the arrows as marks on the camshaft bearing caps, which shows on the outside of the cylinder head.
Install the 4 intake camshaft bearing caps (2) in the order as they was removed.
- Install the 8 intake camshaft bearing cap bolts (1).
-
Courtesy of GENERAL MOTORS COMPANY
Tighten the 8 intake camshaft bearing cap bolts in sequence as shown to 10 N.m (89 lb in).
Remove the EN-50509 fixing tool (1).
Coat all bearing surfaces with engine oil.
- Camshaft Bearing Rear Cap (2) - Install
- Install the 4 camshaft bearing rear cap bolts (1).
-
Courtesy of GENERAL MOTORS COMPANY
Tighten the 4 camshaft rear cap bolts in sequence as shown to 25 N.m (18 lb ft).
Install the EN-51143 fixing tool (1), by carefully turning the hexagon of the camshaft.
Fuel Injection Fuel Rail (2) - Install
- Fuel Injection Fuel Rail Bolt (1) - Install and tighten [2x] 25 N.m (18 lb ft)
- Glow Plug - Install [4x] - Glow Plug Replacement
- Camshaft Sprocket - Install - Camshaft Sprocket Replacement
- Install the exhaust manifold. Exhaust Manifold Replacement
- Install the intake manifold. Intake Manifold Replacement
Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material.
A second technician is required.
The tightening procedure of the timing chain upper guide bolts should be completed within 10 minutes.
Ensure the marks (2) of the camshaft sprocket are aligned.