Installation Procedure
Clean the camshaft housing gasket surface on the cylinder head.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Observe the locations for additional sealer while applying the sealant path.
- The bolts must be installed and fastened to final torque specification immediately after the component is installed.
- Apply a bead of sealant (1) to the timing chain upper cover sealing surface using the following procedure: Adhesives, Fluids, Lubricants, and Sealers
- Begin applying a 6.0 mm (0.236 in) bead, dimension a.
- Continue to apply the bead, decreasing to a 4.0 mm (0.158 in) bead, dimension b, for the remaining bead path, until near the end.
- At the end of the bead path, increase to a 6.0 mm (0.236 in) bead, dimension a.
Engine Front Cover Locating Pin (2) @ Cylinder Head - Install [2x]
- Timing Chain Upper Cover (1) @ Cylinder Head - Install
- Apply sealant to the front threads of the 2 timing chain cover bolts (4).
- Timing Chain Cover Bolt (4) - Install and hand tighten [2x]
- Timing Chain Cover Bolt (3) - Install and hand tighten [4x]
- Timing Chain Cover Bolt (3, 4) - Tighten in sequence [6x] - Fastener Specifications .
- Clean the squeezed out sealant residues between the timing chain upper cover and the cylinder head.
Camshaft Housing Gasket (2) @ Camshaft Housing - Install NEW [2x]
- Camshaft Housing Cover Insulator (3) - Install NEW [26x]
Apply a 6.0 mm (0.236 in) bead of sealant (1) to the camshaft housing sealing locations where the timing chain upper cover joins the cylinder head. Adhesives, Fluids, Lubricants, and Sealers
Camshaft Housing (1) @ Cylinder Head - Install
- Camshaft Housing Bolt (2) - Hand tighten [26x]
Camshaft Housing Bolt (1, 2, 3, 4) - Tighten in sequence [26x] - Fastener Specifications
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Courtesy of GENERAL MOTORS COMPANY
Turbocharger Oil Return Pipe Gasket (5) - Install NEW
- Turbocharger Oil Return Pipe Gasket (6) - Install NEW
- Turbocharger Gasket (3) - Install NEW
- Turbocharger Assembly (1) - Install
- Turbocharger Nut (2, 4) - Install NEW [3x]
- Turbocharger Oil Return Pipe Bolt (8) - Install and tighten [2x] - Fastener Specifications
- Turbocharger Oil Return Pipe Bolt (7) - Install and tighten [2x] - Fastener Specifications
- Lower Crankcase Extension Bolt (9) Install and tighten - Fastener Specifications
- Turbocharger Nut (2, 4) - Tighten [3x] - Fastener Specifications
Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
Positive Crankcase Ventilation Hose (2) - Install
- Positive Crankcase Ventilation Hose Clamp (1) - Engage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Using the EN-47909 Injector Bore and Sleeve Cleaning Kit (1) clean the 6 fuel injector bores in the cylinder head as needed.
Install 6 NEW fuel injector seals (2) and 6 fuel injector washers (3) to the high pressure diesel fuel injectors (1).
- Install the 6 high pressure diesel fuel injectors (1) to the cylinder head.
- NOTE:
Note the mounting position of the fuel injector bracket.
Multiport Fuel Injector Bracket (2) - Install [6x]
- Fuel Injector Bolt (1) - Install [6x]
- Using the EN-45059-A Angle Meter, tighten the 6 fuel injector bolts (1). Fastener Specifications
Fuel Injection Fuel Return Pipe (1) - Install
Fuel Injection Fuel Return Pipe Locking Spring (4) - Engage [6x]
- Retainer (3) - Install
Connect the fuel injector wiring harness using the 8 fuel injector wiring harness retainers (2).
- Connect the 6 high pressure diesel fuel injector electrical connectors (1).
Install the 6 NEW high pressure diesel fuel feed to injector pipes (2).
- Hand tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel rail.
- Hand tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel injectors.
- Tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel rail. Fastener Specifications
- Tighten the 6 high pressure diesel fuel feed to injector pipe fittings (1) at the fuel injectors. Fastener Specifications
Install the fuel injection fuel feed pipe bracket (2).
- Install the fuel injection fuel feed pipe bracket bolt (1) and tighten. Fastener Specifications
Install a NEW high pressure diesel fuel feed to rail pipe (2).
- Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.
Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
- Attach the fuel injector fuel return pipe retainer (2).
Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.
- Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications
Diesel Fuel Separator Bracket Bolt (1) - Install and tighten - Fastener Specifications
- 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.
Camshaft Housing Cover Insulator (1) - Install
Install the EN-52474 Engine Lift Bracket Set.
- Using a suitable engine lifting device, remove the engine from the engine stand.
- Remove the EN-52449 Engine Stand Adapter (2) from the engine.
- Engine Assembly - Install - Engine Removal and Installation (4WD, with RC1, without F47) , or Engine Removal and Installation (2WD, with RC1, without F47) Engine Removal and Installation (4WD, with RC1, with F47) , or Engine Removal and Installation (2WD, with RC1, with F47) , or Engine Removal and Installation (4WD, with WTX, with F47) , or Engine Removal and Installation (2WD, with WTX, with F47) , or Engine Removal and Installation (4WD, with WTX, without F47) , or Engine Removal and Installation (2WD, with WTX, without F47)
Take note that there are different bolt lengths.
Refer to Fastener Caution .