Cylinder Head Replacement
Special Tools
- EN-955-A V-Belt and Timing Tensioner Locking Pin
- EN-45059-A Angle Meter
- EN-51146 Injector Remover/Installer
- EN-51955 Fuel Injector Seal Install/Sizer
- EN-52432 Front Cover Seal Installer
- EN-52433 Injector Remover
- EN-52443 High Pressure Fuel Pump Alignment Tool
- EN-52455 Open End Wrench
- EN-52457 Camshaft Locking Tool
- EN-52458 VCP Locking Tool
- EN-52476 Flywheel Locking Tool
- EN-52483 Cover Installation Guide Pins
Equivalent regional tools: Special Tools
Removal Procedure
Engine Assembly (1) - Remove - Engine Replacement
Oil Filler Cap (1) - Remove
- Intake Manifold Cover (2) - Remove
Exhaust Front Bracket-Upper Position - Remove
Warm Up Three-Way Catalytic Converter Nut (3) - Remove [2x]
- Warm Up Three-Way Catalytic Converter (2) - Remove
- Catalytic Converter Gasket (1) - Remove and DISCARD
- NOTE:
Vertical bolt must be loosened before other two mounting bolts are loosened and removed.
Engine Mount Brace Bolt (1) - Remove and DISCARD
Engine Mount Brace Bolt (1) - Remove and DISCARD [2x]
- Engine Mount Brace (2) - Remove
Turbocharger Coolant Feed Pipe (3) - Remove
- Turbocharger Coolant Feed Pipe Seal (2) - Remove and DISCARD
Turbocharger Coolant Return Pipe (2) - Remove
Turbocharger Oil Return Pipe (4) - Remove
- Turbocharger Oil Return Pipe Gasket (1, 2) - Remove and DISCARD
Turbocharger Wastegate Actuator Vacuum Tank Solenoid Valve Tube (3) - Remove
Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Hose (1) - Remove
Turbocharger Wastegate Regulator Solenoid Valve (1) - Remove
Evaporative Emission Canister Purge Pump (1) - Remove
Intake Manifold (2) - Remove
- Intake Manifold Seal (1) - Remove and DISCARD [3x]
Fuel Pump Cover (1) - Remove
Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
Fuel Pump (1) - Remove
- Fuel Pump Housing Seal (2) - Remove and DISCARD
Fuel Injection Pump Shaft Lifter Roller (1) - Remove
Thermostat Bypass Pipe (2) - Remove
Vacuum Pump (1) - Remove
- Vacuum Pump Gasket (2) - Remove and DISCARD
Water Outlet (1) - Remove
- Water Outlet Gasket (2) - Remove and DISCARD
Ignition Coil (2) - Remove [3x]
Turbocharger Oil Feed Pipe Bolt (1) - Remove
- NOTE:
DO NOT remove the positive crankcase ventilation vacuum hose unless replacement of the hose is necessary.
- The positive crankcase ventilation vacuum hose clamps are tamper-proof connections.
- The turbocharger must be removed in order to install the positive crankcase ventilation vacuum hose at the turbocharger.
- The camshaft cover, turbocharger, and vacuum hose can be removed together as an assembly and set aside so long as the tamper-proof connection remains intact.
- The camshaft cover or turbocharger can be removed and set aside so long as the vacuum hose connection remains intact and undamaged.
Remove the Camshaft Cover (1), Turbocharger (2), Positive Crankcase Ventilation Vacuum Hose (3) as an assembly.
Turbocharger Gasket (2) - Remove
Turbocharger Oil Feed Pipe (1) - Remove
- Turbocharger Oil Feed Pipe Seal Ring (3) - Remove and DISCARD
Fuel Injection Fuel Rail Bolt (1) - Remove [4x]
- Fuel Injector Retainer (2) - Remove and DISCARD [3x]
Cable Tie (3) - Remove and DISCARD [4x]
- Remove the tape. (2)
- Electrical Connector (1) @ Fuel Injection Fuel Rail Fuel Pressure Sensor - Disconnect
- Direct Fuel Injection Fuel Rail (4) - Remove
Electrical Connector (2) @ Direct Fuel Injector - Disconnect [3x]
- Fuel Injector Wiring Harness (1) - Remove
EN-52433 Injector Remover (2) @ EN-51146-1-3 slide hammer (1) - Assemble
- EN-52433 Injector Remover (2) @ Fuel Injector (3) - Install
- Direct Fuel Injector (3) - Remove [3x] - Use EN-51146-1-3 slide hammer
- Remove the special tools.
Fuel Injector Seal Retainer - White (1) - Remove [3x]
- Fuel Injector Seal Retainer - Red (2) - Remove [3x]
- Combustion Fuel Injector Seal (3) - Remove and DISCARD [3x]
Drive Belt Tensioner (2) - Remove
Starter (3) - Remove
- NOTE:
Ensure the EN-52476 Flywheel Locking Tool (1) is properly assembled, and the timing pin plunger (3) is retracted. When using the EN-52476 Flywheel Locking Tool as a locking device, adjust the pawl armature (4) to fully engage the teeth once installed.
EN-52476 Flywheel Locking Tool (1) - Install
- Bolt (2) - Install and tighten [2x]
- Adjust the pawl armature (4) on the EN-52476 Flywheel Locking Tool to fully engage the teeth.
Crankshaft Balancer Bolt (3) - Remove and DISCARD
- Crankshaft Balancer (1) - Remove
Camshaft Position Actuator Solenoid Valve Solenoid (2) - Remove
- Seal (1) @ Camshaft Position Actuator Solenoid Valve Solenoid - Remove and DISCARD [2x]
Timing Belt Lower Cover Bolt (1) - Remove [9x]
- Loosen the timing belt lower cover carefully from the engine, use a suitable tool at the 2 locations (2, 3)
Timing Belt Lower Cover (1) - Remove and DISCARD
If the engine timing is adjusted correctly, the valves (1, 3) of the 3rd cylinder must be closed. Also the 2 flats (2) must stand in vertical position.
- NOTE:
The EN-52457 Camshaft Locking Tool has an identification for which side it must be used. Place the EN-52457 Camshaft Locking Tool with the identification mark I (1) facing upwards. Also the surface has an identification for the intake (2).
EN-52457-2 Locking Tool - Intake (5) - Install
- Bolt (3, 4) - Install and tighten
- NOTE:
The EN-52457 Camshaft Locking Tool has an identification for which side it must be used. Place the EN-52457 Camshaft Locking Tool with the identification mark I (1) facing upwards. Also the surface has an identification for the exhaust (2).
EN-52457-2 Locking Tool - Exhaust (5) - Install
- Bolt (3, 4) - Install and tighten [2x]
Bolt @ EN-52458 VCP Locking Tool (2) - Loosen
- EN-52458 VCP Locking Tool (1) - Adjust
- EN-52458 VCP Locking Tool (1) - Install
- Bolt (3) - Install and tighten [4x] 6 N.m (53 lb in)
- Bolt (2) - Tighten
Loosen the timing belt tensioner bolt (2) and release the tension from the timing belt tensioner (1). Rotate the timing belt tensioner counter-clockwise.
- EN-955-10-A locking pin (3) - Install
Install the EN-52458-3 locking tool (2) to the holes in the camshaft sprocket.
- Check that the EN-52458-3 locking tool (2) sits correctly in the hole of the camshaft sprocket.
- Bolt (3, 4) - Tighten [2x] 20 N.m (15 lb ft)
- Camshaft Sprocket Actuator Valve Bolt (1) - Loosen [2x]
- Bolt (3, 4) - Loosen [2x]
Bolt (3) - Remove [4x]
- EN-52458 locking tool (1) - Remove
Camshaft Sprocket Actuator Valve Bolt (1) - Remove and DISCARD [2x]
Camshaft Sprocket (1) - Remove [2x]
Timing Belt Tensioner Bolt (2) - Remove
- Timing Belt Tensioner (1) - Remove
- Timing Belt Idler Pulley Bolt (3) - Loosen
- Timing Belt Idler Pulley (4) - Remove
Crankshaft Balancer Bolt (4) - Remove
- Crankshaft Sprocket (3) - Remove
- Crankshaft Front Oil Seal (2) - Remove and DISCARD
- Remove the timing belt (1) upwards.
Bolt (3, 4) - Remove [2x]
- EN-52457-2 Locking Tool - Exhaust (5) - Remove
Bolt (3, 4) - Remove
- EN-52457-2 Locking Tool - Intake (5) - Remove
Bolt (2) - Remove [2x]
- EN-52476 Flywheel Locking Tool (1) - Remove
-
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NOTE:Many internal engine components will develop specific wear patterns on their friction surfaces.
- The components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
- Tag or mark each part immediately when removed. Indicate the location, direction, or orientation when necessary.
Loosen the 10 camshaft bearing cap bolts (1) in sequence as shown in steps of 1/2 turn.
Camshaft Bearing Cap Bolt (2) - Remove [10x]
- Camshaft Bearing Front Cap (1) - Remove
- Camshaft Bearing Cap (3) - Remove [4x]
- Intake Camshaft (4) - Remove
-
Courtesy of GENERAL MOTORS COMPANY
NOTE:Many internal engine components will develop specific wear patterns on their friction surfaces.
- The components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
- Tag or mark each part immediately when removed. Indicate the location, direction, or orientation when necessary.
Loosen the 8 camshaft bearing cap bolts (1) in sequence as shown in steps of 1/2 turn.
Camshaft Bearing Cap Bolt (2) - Remove [8x]
- Camshaft Bearing Front Cap (3) - Remove
- Camshaft Bearing Cap (1) - Remove [3x]
- Exhaust Camshaft (4) - Remove
- NOTE:
Bolt (1) is longer than the other bolts shown.
Cylinder Head Bolt (1, 2, 3) - Remove [6x]
-
Loosen the cylinder head bolts (3) in sequence as shown in steps of 1/2 turn
- Cylinder Head Bolt (1) - Remove and DISCARD [8x]
Cylinder Head (1) - Remove
- Cylinder Head Gasket (2) - Remove and DISCARD
- Cylinder Head - Disassemble - Cylinder Head Disassemble
- Clean and inspect the cylinder head. Cylinder Head Cleaning and Inspection
Installation Procedure
- Cylinder Head - Assemble - Cylinder Head Assemble
Cylinder Head Gasket (2) - Install NEW
- Cylinder Head (1) - Install
-
CAUTION:CAUTION:
Cylinder Head Bolt (1) - Install NEW [8x]
- Cylinder Head Bolt (1) - Tighten in sequence [8x]
- First Pass: 30 N.m (22 lb ft)
- Second Pass: 90 degrees - Use the special tool: EN-45059-A Angle Meter
- Final Pass: 60 degrees - Use the special tool: EN-45059-A Angle Meter
- NOTE:
The bolt (1) is longer than all other bolts.
Cylinder Head Bolt (1, 2, 3) - Install and tighten [6x] 15 N.m (11 lb ft)
Coat the intake camshaft (4) and the camshaft bearing caps (1, 3) with engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Exhaust Camshaft (4) - Install
- Camshaft Bearing Cap (3) - Install [3x]
- Camshaft Bearing Front Cap (1) - Install
- Camshaft Bearing Cap Bolt (2) - Loosely install [8x]
-
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Camshaft Bearing Cap Bolt (1) - Tighten in sequence [8x]
- First Pass: 8 N.m (71 lb in)
- Second Pass: Loosen 180 degrees
- Third Pass: 12 N.m (106 lb in)
- Final Pass: 12 N.m (106 lb in)
Coat the intake camshaft (4) and the camshaft bearing caps (1, 3) with engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Intake Camshaft (4) - Install
- Camshaft Bearing Cap (3) - Install [4x]
- Camshaft Bearing Front Cap (1) - Install
- Camshaft Bearing Cap Bolt (2) - Loosely install [10x]
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Camshaft Bearing Cap Bolt (1) - Tighten in sequence [10x]
- First Pass: 8 N.m (71 lb in)
- Second Pass: Loosen 180 degrees
- Third Pass: 12 N.m (106 lb in)
- Final Pass: 12 N.m (106 lb in)
- NOTE:
Ensure the EN-52476 Flywheel Lock Tool (1) is properly assembled, and the timing pin plunger (3) is retracted. When using the EN-52476 Flywheel Lock Tool as an timing device, adjust the pawl armature (4) so the pawl is not engaging the teeth once installed.
EN-52476 Flywheel Lock Tool (1) - Install
- Bolt (2) - Install and tighten [2x]
Crankshaft Balancer Bolt (1) - Install
- Engage the EN-52476 Flywheel Lock Tool timing pin plunger (2).
- Adjust the engine to the engine timing position. Use the crankshaft balancer bolt to slowly rotate the crankshaft in direction of engine rotation until the pin (3) of the EN-52476 Flywheel Lock Tool snaps automatically into the hole (4) of the automatic transmission flex plate or the engine flywheel.
- Adjust the pawl armature (5) on the EN-52476 Flywheel Lock Tool so the pawl is not engaging the teeth.
Adjust the intake camshaft so that the valves (3) of the 3rd cylinder are closed and the 2 flats (2) stand in vertical position. Use the EN-52455 Open End Wrench (1).
- NOTE:
The EN-52457 Camshaft Locking Tool has an identification for which side of the tool must be facing upward. Place the EN-52457 Camshaft Locking Tool with the I (1) facing upwards. The surface of the tool will also have the identification intake (2) for use on the intake camshaft.
EN-52457-2 locking tool (5) @ Intake Camshaft - Install
- Bolt (3, 4) - Install and tighten
Adjust the exhaust camshaft so that the valves (3) of the 3rd cylinder are closed and the 2 flats (2) stand in vertical position. Use the EN-52455 Open End Wrench (1)
- NOTE:
The EN-52457 Camshaft Locking Tool has an identification for which side of the tool must be facing upward. Place the EN-52457 Camshaft Locking Tool with the I (1) facing upwards. The surface of the tool will also have the identification exhaust (2) for use on the exhaust camshaft.
EN-52457-1 locking tool (5) @ Exhaust Camshaft - Install
- Bolt (3, 4) - Install and tighten [2x]
Install the timing belt (1) downwards.
- Crankshaft Front Oil Seal (2) - Install NEW
- Crankshaft Sprocket (3) - Install
- Crankshaft Balancer Bolt (4) - Install
- NOTE:
The front of the camshaft sprockets is recognizable by the pin (2).
Camshaft Sprocket (1) - Install [2x]
- NOTE:
The sprocket bolts must be tightened enough to remove axial play between the sprocket and cam. The bolts must be loose enough to allow the sprocket to turn independently of camshafts.
Camshaft Sprocket Actuator Valve Bolt (1) - Install NEW and hand tighten [2x]
Timing Belt Tensioner (1) - Install
- Timing Belt Tensioner Bolt (2) - Loosely install
- Timing Belt Idler Pulley (4) - Install
- Timing Belt Idler Pulley Bolt (3) - Install and tighten 36 N.m (27 lb ft)
EN-955-10-A pin (2) - Remove
- Rotate the timing belt tensioner clockwise to tension the timing belt tensioner (1) to the nominal position (4), and an additional 10 degrees (5).
- Timing Belt Tensioner Bolt (3) - Tighten 36 N.m (27 lb ft)
Bolt (2) - Loosen
- Slide the EN-52458 VCP Locking Tool (1) apart.
- EN-52458 VCP Locking Tool (1) - Install
- Bolt (3) - Install and tighten [4x] 6 N.m (53 lb in)
- Bolt (2) - Tighten
Install the EN-52458-3 locking tool (2) to the holes in the intake camshaft sprocket.
- Check that the EN-52458-3 locking tool (2) sits correctly in the hole of the camshaft sprocket.
- Tighten the EN-52458-3 locking tool (2) to 20 N.m (15 lb ft). Rotate the EN-52458-3 locking tool counter-clockwise.
- While holding the EN-52458-3 locking tool to 20 N.m (15 lb ft), tighten the bolt (3) to 20 N.m (15 lb ft).
- Camshaft Sprocket Actuator Valve Bolt (1) @ Intake Camshaft - Tighten
- First Pass: 50 N.m (37 lb ft)
- Final Pass: 28 degrees, use the EN-45059 meter
Install the EN-52458-3 locking tool (3) to the holes in the exhaust camshaft sprocket.
- Check that the EN-52458-3 locking tool (3) sits correctly in the hole of the camshaft sprocket.
- Tighten the EN-52458-3 locking tool (3) to 20 N.m (15 lb ft). Rotate the EN-52458-3 locking tool counter-clockwise.
- While holding the EN-52458-3 locking tool to 20 N.m (15 lb ft), tighten the bolt (2) to 20 N.m (15 lb ft).
- Camshaft Sprocket Actuator Valve Bolt (1) @ Exhaust Camshaft - Tighten
- First Pass: 50 N.m (37 lb ft)
- Final Pass: 28 degrees, use the EN-45059 meter
Bolt (3) - Remove [4x]
- EN-52458 locking tool (1) - Remove
Bolt (3, 4) - Remove [2x]
- EN-52457-1 locking tool (5) - Remove
Bolt (3, 4) - Remove
- EN-52457-2 locking tool (5) - Remove
Turn the crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer bolt (1) until the pin (2) of the EN-52476 lock tool snaps automatically into the hole (3) of the automatic transmission flex plate or the engine flywheel.
- NOTE:
The nominal position of the timing belt tensioner is when the mobile index (2) sits in the middle between the gap of the front plate (3). A tolerance is given when half of the hole (4) is visible (+/- 5 degrees).
Check that the timing belt tensioner (1) is in the nominal position.
- If not, repeat the step to adjust the tensioner.
- NOTE:
The EN-52457 Camshaft Locking Tool has an identification for which side of the tool must be facing upward. Place the EN-52457 Camshaft Locking Tool with the I (1) facing upwards. The surface of the tool will also have the identification intake (2) for use on the intake camshaft.
EN-52457-2 locking tool (5) @ Intake Camshaft - Install
- NOTE:
The EN-52457 Camshaft Locking Tool has an identification for which side of the tool must be facing upward. Place the EN-52457 Camshaft Locking Tool with the I (1) facing upwards. The surface of the tool will also have the identification exhaust (2) for use on the exhaust camshaft.
EN-52457-2 locking tool (5) - Install
- If the EN-52457 Camshaft Locking Tool can be installed, the engine timing is properly adjusted.
- If the EN-52457 Camshaft Locking Tool can not be installed, repeat the steps to set the engine timing.
- EN-52457 Camshaft Locking Tool - Remove
Crankshaft Balancer Bolt (1) - Remove
- Clean all sealing surfaces.
Ensure proper use of room temperature vulcanizing (RTV) sealant. - Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- All sealing surfaces must be free of contamination prior to applying the sealant.
- Installation and final torque specification must be completed within 10 minutes of applying the sealant.
- Apply a 4 mm (0.16 in) bead of sealant (1) to the timing belt lower cover. Adhesives, Fluids, Lubricants, and Sealers
EN-52432 Front Cover Seal Installer (1) @ Crankshaft - Install
- NOTE:
Use EN-52483 Cover Installation Guide Pins (2) to help align the cover with the locating pins and the EN-52432 Front Cover Seal Installer (3).
EN-52483 Cover Installation Guide Pins (2) - Install
- Timing Belt Lower Cover (1) - Install NEW
- EN-52483 Cover Installation Guide Pins (2) - Remove
-
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Engine Front Cover Bolt (1) - Loosely install [9x]
- Engine Front Cover Bolt (1) - Tighten in sequence [9x]
- First Pass: 4 N.m (35 lb in)
- Final Pass: 8.5 N.m (75 lb in)
- EN-52432 Front Cover Seal Installer (2) @ Crankshaft - Remove
Seal (1) @ Camshaft Position Actuator Solenoid Valve Solenoid - Lubricate Adhesives, Fluids, Lubricants, and Sealers
- Seal (1) @ Camshaft Position Actuator Solenoid Valve Solenoid - Install NEW [2x]
- Camshaft Position Actuator Solenoid Valve Solenoid (2) - Install [2x]
- Camshaft Position Actuator Solenoid Valve Bolt (3) - Install and tighten [4x] 8.5 N.m (75 lb in)
- NOTE:
Check that the notch of the crankshaft balancer sits correct in the key (2).
Crankshaft Balancer (1) - Install
- Crankshaft Balancer Bolt (3) - Install NEW - Do NOT tighten.
- Tighten the crankshaft balancer bolt to 150 N.m (111 lb ft)
- Tighten the crankshaft balancer bolt an additional 150 degrees, use the EN-45059 Angle Meter while fixing the crankshaft balancer.
EN-52476 Flywheel Locking Tool - Remove
Starter (3) - Install
- Starter Stud (2) - Install and tighten 58 N.m (43 lb ft)
- Starter Bolt (1) - Install and tighten 58 N.m (43 lb ft)
Drive Belt Tensioner (2) - Install
- Drive Belt Tensioner Bolt (1) - Install and tighten 22 N.m (16 lb ft) [2x]
- Clean the fuel injector bores and clean the fuel injectors, if the fuel injectors will be re-installed. Direct Fuel Injection Fuel Rail Cleaning and Inspection
Fuel Injector Wiring Harness (1) - Install
- Electrical Connector (2) @ Fuel Injection Fuel Rail Fuel Pressure Sensor - Connect
- Install the NEW tape. (3)
- Cable Tie (4) - Install NEW [4x]
- NOTE:
Do NOT use any type of lubricant when installing the NEW combustion fuel injector seal on the fuel injector tip.
NOTE:Only one combustion fuel injector seal is used on each direct fuel injector, located on the recessed area of the fuel injector tip closest to the end.
Install the EN-51955-2 short protector (4) onto the fuel injector tip. Place a NEW combustion fuel injector seal (2) on the EN-51955-2 short protector (4).
- Using the EN-51955-4 pusher (3), install the combustion fuel injector seal (2) into the recessed area (1) of the fuel injector, then remove the EN-51955-2 short protector.
Compress the combustion fuel injector seal (1) using the EN-51955-3 pre-sizer (2).
Using the EN-51955-5 Fuel Injector Seal Sizer (2), resize the combustion fuel injector seal (1).
- Install a combustion fuel injector seal on each of the remaining direct fuel injectors using the same procedure.
- NOTE:
Check that the gaps of the two fuel injector seal retainers are aligned.
Fuel Injector Seal Retainer - Red (3) - Install [3x]
- Fuel Injector Seal Retainer - White (2) - Install [3x]
- Fuel Injector Seal (1) - Install NEW [3x]
- NOTE:
- Lubricate the fuel injector seal with engine oil.
- Note the orientation of the fuel injector retainers when installed.
Direct Fuel Injector (3) @ Direct Fuel Injection Fuel Rail (1) - Install [3x]
- Connect the electrical connector. (4) [3x]
- Fuel Injector Retainer (2) - Install NEW [3x]
Direct Fuel Injection Fuel Rail (2) - Install
- Fuel Injection Fuel Rail Bolt (1) - Loosely install [4x]
- NOTE:
Tighten only the 2 fuel injection fuel rail bolts shown until the direct fuel injection fuel rail is seated to the cylinder head.
Tighten the fuel injection fuel rail bolt (1) by hand 1/2 turn.
- Tighten the fuel injection fuel rail bolt (2) by hand 1/2 turn.
- Continue to tighten these two bolts by hand in 1/2 turn increments until the direct fuel injection fuel rail is seated to the cylinder head.
-
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Fuel Injection Fuel Rail Bolt (1) - Tighten in sequence [4x] 36 N.m (27 lb ft)
Turbocharger Oil Feed Pipe Seal Ring (3) - Install NEW
- Turbocharger Oil Feed Pipe Seal Ring (3) - Lubricate Adhesives, Fluids, Lubricants, and Sealers
- Turbocharger Oil Feed Pipe (1) - Install
- Turbocharger Oil Feed Pipe Bolt (2) - Install and tighten 8.5 N.m (75 lb in)
Turbocharger Gasket (2) - Install
- Turbocharger Gasket Bolt (1) - Install and tighten 8.5 N.m (75 lb in)
Install the Camshaft Cover (1), Turbocharger (2), Positive Crankcase Ventilation Vacuum Hose (3) as an assembly.
-
Turbocharger Nut (1) - Tighten in sequence [4x]
- First Pass: 15 N.m (11 lb ft)
- Second Pass: 20 N.m (15 lb ft)
- Final Pass: 60 degrees - Use the EN-45059-A Angle Meter
-
Camshaft Cover Bolt (1) - Install and hand tighten [17x]
- Camshaft Cover Bolt (1) - Tighten in sequence [17x]
- First Pass: 4 N.m (35 lb in)
- Final Pass: 8.5 N.m (75 lb in)
Turbocharger Oil Feed Pipe Bolt (1) - Tighten
- First Pass: 10 N.m (89 lb in)
- Final Pass: 40 N.m (30 lb ft)
Water Outlet Gasket (2) - Install NEW
- Water Outlet (1) - Install
- Water Outlet Bolt (3) - Install and tighten [3x] 8.5 N.m (75 lb in)
Vacuum Pump Gasket (2) - Install NEW
- Vacuum Pump (1) - Install
- Vacuum Pump Bolt (3) - Install and hand tighten [3x]
-
Vacuum Pump Bolt (1) - Tighten in sequence [3x]
- First Pass: 7 N.m (62 lb in)
- Final Pass: 15 N.m (11 lb ft)
Thermostat Bypass Pipe (2) - Install
- Thermostat Bypass Pipe Bolt (1, 3) - Install and tighten [2x] 8.5 N.m (75 lb in)
The EN-52443 High Pressure Fuel Pump Alignment Tool has two ends marked with Number 1 (1) and Number 2 (2).
- NOTE:
- The camshaft MUST be at the base circle position before the fuel pump is installed.
- At the base circle position, the EN-52443 High Pressure Fuel Pump Alignment Tool will sit flush with the cylinder head.
Install the EN-52443 High Pressure Fuel Pump Alignment Tool (2) with the Number 1 (1) on the outside and turn the crankshaft until the camshaft lobe is at the base circle position.
- Remove the EN-52443 High Pressure Fuel Pump Alignment Tool (2).
Lubricate the fuel injection pump shaft lifter roller (1) with engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Fuel Injection Pump Shaft Lifter Roller (1) - Install
Fuel Pump Housing Seal (2) - Install NEW
- Fuel Pump (1) - Install
- Fuel Pump Bolt (3) - Install and tighten [2x] 36 N.m (27 lb ft)
Fuel Injection Fuel Feed Pipe - Install NEW
- Fuel Injection Fuel Feed Pipe Bolt (2) - Install and tighten 8.5 N.m (75 lb in)
- Fuel Injection Fuel Feed Front Pipe Nut (1) - Tighten 30 N.m (22 lb ft) [2x]
Fuel Pump Cover (1) - Install
- Fuel Pump Shield Bolt (2) - Install and tighten [3x] 8.5 N.m (75 lb in)
Wiring Harness Clip (1) - Install
Intake Manifold Seal (4) - Install NEW [3x]
- Intake Manifold (2) - Install
-
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Intake Manifold Bolt (1) - Install [4x]
- Intake Manifold Bolt (1) - Tighten in sequence [4x]
- First Pass: 7 N.m (62 lb in)
- Final Pass: 15 N.m (11 lb ft)
- Intake Manifold Bolt (1) - Tighten 15 N.m (11 lb ft) [4x]
Evaporative Emission Canister Purge Pump (1) - Install
- Evaporative Emission Canister Purge Pump Bolt (2) - Install and tighten 15 N.m (11 lb in) [2x]
Turbocharger Wastegate Regulator Solenoid Valve (1) - Install
- Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Bolt (2) - Install and tighten [2x] 15 N.m (11 lb ft)
Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Hose (1) - Install
- Clip (3) - Install
- Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Hose (1) @ Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve (6) - Install
- Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Hose (1) @ Vacuum Pump (5) - Install
- Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Hose (1) @ Camshaft Cover (2) - Install
Turbocharger Wastegate Actuator Vacuum Tank Solenoid Valve Tube (3) - Install
- Turbocharger Wastegate Actuator Vacuum Tank Solenoid Valve Tube (3) @ Clip (4) - Install
- Clip (1) - Install
- Turbocharger Wastegate Actuator Vacuum Tank Solenoid Valve Tube (3) @ Camshaft Cover (2, 5) - Install [2x]
- Turbocharger Wastegate Actuator Vacuum Tank Solenoid Valve Tube (3) @ Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve (6) - Install
Turbocharger Oil Return Pipe Gasket (1, 2) - Install NEW [2x]
- Turbocharger Oil Return Pipe (4) - Install
- Turbocharger Oil Return Pipe Bolt (3, 5) - Install and tighten [4x] 8.5 N.m (75 lb in)
Turbocharger Coolant Return Pipe (2) - Install
- Clamp (4) - Install - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Return Pipe Bolt (1, 3) - Install and tighten [2x] 8.5 N.m (75 lb in)
Turbocharger Coolant Return Pipe (1) @ Water Outlet (2) - Install [2x]
- Clamp (3) - Install [2x] - Hose Clamp Replacement Guidelines - Spring Type
Turbocharger Coolant Feed Pipe Seal (2) - Install NEW
- Turbocharger Coolant Feed Pipe Seal (2) - Lubricate Adhesives, Fluids, Lubricants, and Sealers
- Turbocharger Coolant Feed Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed Pipe (3) - Install
Turbocharger Coolant Feed Pipe Bolt (1) - Install and tighten 15 N.m (11 lb ft)
Engine Mount Brace (2) - Install
- Engine Mount Brace Bolt (1) - Install NEW and tighten [2x]
- First Pass: 30 N.m (22 lb ft)
- Final Pass: 60-75 degrees
- NOTE:
Vertical bolt must be left loose until other two engine mount brace bolts are tightened
Engine Mount Brace Bolt (1) - Install NEW and tighten
- First Pass: 25 N.m (18 lb ft)
- Final Pass: 45-60 degrees
Catalytic Converter Gasket (1) - Install a NEW gasket.
- Exhaust Front Bracket-Lower Position (3) - Install and tighten 22 N.m (16 lb ft) [2x]
Exhaust Front Bracket-Upper Position - Install
- Exhaust Front Bracket Nut (1) Install and tighten 22 N.m (16 lb ft) [2x]
- Exhaust Front Bracket Bolt (2) - Install and tighten 22 N.m (16 lb ft)
- Exhaust Pipe Clamp - Install and tighten 15 N.m (11 lb ft)
Intake Manifold Cover (2) - Install
- Oil Filler Cap (1) - Install
Engine Assembly (1) - Install - Engine Replacement
- Fill the cooling system. Cooling System Draining and Filling (GE-47716) , or Cooling System Draining and Filling (Static)
- Start the engine and check for leaks.
Ensure that the caps are installed in their original location and position.
Ensure that the caps are installed in their original location and position.
The engine timing is located 118.14 degrees after top dead center.
Once there is resistance, do NOT turn the crankshaft further.
10 degrees past nominal position can be verified when the hole in the mobile index pointer is no longer visible behind the gap of the front plate.
A second technician is required.
A second technician is required.
DO NOT allow cleaning solvents to come in contact with either the timing belt or oil pump belt.
In case of a Turbocharger Replacement, use a NEW Turbocharger Oil Feed Pipe.
The fuel pump flange must be fully seated to the cylinder head.
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.
Check that the locating pins (1, 3) sit correct in their hole.
Tighten without sequence.
Refer to Torque-to-Yield Fastener Warning .
Tighten the two engine mount brace bolts before tightening the vertical bolt