Installation Procedure
EN-52586 Crankshaft Fixing Pin (4) - Remove
- Rotate the crankshaft until cylinder 1 is at top dead center.
- Measure the piston overlap:
- NOTE:
A magnetic dial indicator base may be used at an adjacent piston bore attaching to the steel cylinder sleeve.
Install the EN-571-B Dial Gauge (1) with a suitable base.
- Zero the EN-571-B Dial Gauge (1) to the cylinder head deck surface.
- Place the EN-571-B Dial Gauge (1) pointer on the piston at the first measurement point as shown. Be sure the pointer is directly above the piston pin centerline to prevent inaccurate readings from piston rocking.
- Measure and note the piston overlap of the cylinder 1, first measurement.
Place the EN-571-B Dial Gauge (1) pointer on the piston at the second measure point as shown. Be sure the pointer is directly above the piston pin centerline to prevent inaccurate readings from piston rocking.
- Measure and note the piston overlap of the cylinder 1, second measurement.
- Then repeat the procedure for the cylinder 6.
Use the crankshaft pulley bolt (1) to turn the crankshaft (2) 120 degrees.
- Measure and note the piston overlap with the same 2 measure points at the cylinder 2 and cylinder 5.
- Turn the crankshaft 120 degrees.
- Measure and note the piston overlap with the same 2 measure points at the cylinder 3 and cylinder 4.
- The largest piston overlap 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 (0.004 in).
After the measurement of the piston overlap on all pistons, select the cylinder head gasket with the correct identification marks:
- Piston overlap 0.434 - 0.549 mm (0.017 - 0.022 in), choose cylinder head gasket with identification mark on Position (3), thickness 1.30 mm (0.051 in).
- Piston overlap 0.550 - 0.664 mm (0.022 - 0.026 in), choose cylinder head gasket with identification mark on Position (2), thickness 1.40 mm (0.055 in).
- Piston overlap 0.665 - 0.778 mm (0.026 - 0.031 in), choose cylinder head gasket with identification mark on Position (1), thickness 1.50 mm (0.059 in).
Rotate the crankshaft with a suitable tool in the direction of the arrow at the crankshaft pulley bolts (1), until the following alignment is achieved:
- The crankshaft locking divot (2) aligns with the engine block (3)
- The crankshaft timing mark, dimension a, is at 40 degrees TDC
- Install the EN-52586 Crankshaft Fixing Pin (4).
Camshaft Bearing Cap Bolt (1) - Remove [16x]
- NOTE:
- Many internal engine components will develop specific wear patterns on their friction surfaces.
- 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.
Camshaft Bearing Rear Cap (1) - Remove
- Camshaft Bearing Cap (2) - Remove [6x]
Camshaft Bearing Cap Bolt (1) - Remove [12x]
Camshaft Bearing Cap (2) - Remove [6x]
Coat the exhaust camshaft with engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Exhaust Camshaft (3) - Install
- Lubricate the 6 camshaft bearing caps (2) with engine oil.
- Camshaft Bearing Cap (2) - Install [6x]
- CAUTION:
Refer to Fastener Caution .
Camshaft Bearing Cap Bolt (1) - Install and tighten in sequence [12x] - Fastener Specifications
Coat the intake camshaft with engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Intake Camshaft (4) - Install
- Lubricate the 6 camshaft bearing caps (2) and the camshaft bearing rear cap (1) with engine oil.
- Camshaft Bearing Rear Cap (1) - Install
- Camshaft Bearing Cap (2) - Install [6x]
Camshaft Bearing Cap Bolt (1) @ Intake Camshaft - Install and tighten in sequence [16x] - Fastener Specifications
- Rotate both camshaft timing notches to the 12 o'clock position.
-
Courtesy of GENERAL MOTORS COMPANY
Install the EN-52445-1 Camshaft Tool (3) to the camshaft housing.
- Check that the tab (1) of the EN-52445-1 Camshaft Tool sits correctly under the camshaft bearing rear cap (2).
- Check that the pins (6) of the EN-52445-1 Camshaft Tool sit correctly in the camshafts (5).
Install the EN-52445-2 Camshaft Tool (1) on the camshafts.
Install the 2 J-43301 Coil Pack Pullers (1).
- NOTE:
- Do not use any type of sealant on the cylinder head gasket.
- The cylinder head gaskets must be installed in the proper direction and position.
Cylinder Head Gasket (2) - Install NEW
- Cylinder Head (1) - Install
Cylinder Head Bolt (1) - Install NEW [14x]
- Cylinder Head Bolt (1) - Tighten in sequence [14x] - Fastener Specifications
- Cylinder Head Bolt (2) - Install and tighten [3x] - Fastener Specifications
- Lubricate the 24 hydraulic valve lash adjusters and valve rocker arms with engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Check that the valve lash adjusters and valve rockers are properly installed to the cylinder head.
Camshaft Housing Gasket (4) - Install NEW
- Camshaft Housing Gasket (3) - Install NEW [6x]
- Camshaft Housing (1) - Install
-
Courtesy of GENERAL MOTORS COMPANY
Hand tighten the 6 bolts (4) in the sequence shown.
Camshaft Housing Bolt (1) - Install and hand tighten [16x]
- Camshaft Housing Bolt (1) - Tighten in sequence - Fastener Specifications
Timing Chain Guide (1) - Install
- If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Timing Chain Guide Bolt (2) - Install and tighten - Fastener Specifications
Camshaft Sprocket (2) - Install
- Camshaft Sprocket Bolt (1) - Install NEW
- Camshaft Sprocket Bolt (1) - Hand tighten
Secondary Timing Chain (1) - Install
Timing Chain Guide (1) - Install
- If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Timing Chain Guide Bolt (2) - Install and tighten [2x] - Fastener Specifications
Camshaft Sprocket (2) - Install
- Camshaft Position Sensor Exciter Wheel (1) - Install
- Camshaft Sprocket Bolt (3) - Install NEW and hand tighten
- NOTE:
Check that the nose of the EN-52445-3 Camshaft Tool sits correct in the gap (2) of the camshaft position sensor exciter wheel (3).
Install the EN-52445-3 Camshaft Tool (1) to both camshafts.
Camshaft Sprocket Bolt (1) - Tighten [2x] - Fastener Specifications
Timing Chain Tensioner Gasket (1) - Install NEW
- Timing Chain Tensioner (2) - Install and tighten - Fastener Specifications
Remove the EN-52234 Timing Chain Tensioner Retaining Pin (2).
Remove the EN-52445-3 Camshaft Tool Holder (2).
- Remove the EN-52445-2 Camshaft Tool Holder (3).
Remove the 2 J-43301 Coil Pack Pullers (1).
-
Remove the EN-52445-1 Camshaft Tool (3) from the camshaft housing.
EN-52586 Crankshaft Fixing Pin (4) - Remove
- Rotate the engine by hand to ensure there is no interference.
- Crankshaft Pulley Bolt (1) - Remove [4x]
Clean all sealing surfaces.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Apply a bead of sealant (1) to the crankshaft front oil seal sealing surface using the following procedure: Adhesives, Fluids, Lubricants, and Sealers
- Begin applying a 4.0 mm (0.158 in) bead, dimension a.
- Continue to apply the bead, increasing to a 6.0 mm (0.236 in) bead, dimension b.
- Continue to apply the bead, decreasing to a 4.0 mm (0.158 in) bead, dimension a.
- At the end of the bead path, increase to a 6.0 mm (0.236 in) bead, dimension a.
Install the EN-52452 Front Crankshaft Seal Installer (1) to the crankshaft.
- Install and hand tighten the 2 bolts (2) of the EN-52452 Front Crankshaft Seal Installer (1).
Crankshaft Front Oil Seal (1) - Install NEW
- Check that the crankshaft front oil seal (1) sits correctly on the crankshaft and the 2 pins (2, 4).
- Remove the 2 bolts (5) from the EN-52452 Front Crankshaft Seal Installer (3).
- Remove the EN-52452 Front Crankshaft Seal Installer (3) from the crankshaft.
Engine Front Cover Bolt (1) - Install and tighten in sequence [8x] - Fastener Specifications
Crankshaft Pulley (1) - Install
- Crankshaft Pulley Bolt (2) - Install and hand tighten [4x]
Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
- Crankshaft Pulley Bolt (2) - Tighten [4x] - Fastener Specifications
Camshaft Position Sensor (2) - Install
- Camshaft Position Sensor Bolt (1) - Install and tighten - Fastener Specifications
Cylinder Head Temperature Sensor (1) - Install and tighten - Fastener Specifications
Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- 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.
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
- NOTE:
The ceramic glow plug technology is sensitive to collision, drops, or general impact. Avoid side force or the bending of the tip during the installation in the head. Replace the glow plug if one or more of these conditions is suspected.
- Glow plugs must be discarded whenever removed, and replaced with NEW.
- If the cylinder head is removed, the accompanying glow plugs must be discarded and replaced with NEW.
- Handle with extreme care, do not allow glow plugs to touch each other.
- Do not use power tools to install glow plugs.
- Use a suitable, commercially available glow plug socket.
- First install glow plugs by hand at least 3 turns into the cylinder head.
- Avoid canting of the glow plugs during the insertion process into the cylinder head.
Glow Plug (1) - Install [6x] - Fastener Specifications
Intake Manifold Gasket (3) - Install NEW [6x]
- Intake Manifold (1) - Install
- Intake Manifold Bolt (2) - Install and hand tighten [9x]
- Intake Manifold Bolt (2) - Tighten in sequence [9x] - 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.
Intake Manifold Cover (1) - Install
- Intake Manifold Cover Retainer (2) - Install [2x]
Fuel Injection Fuel Rail Stud (1) - Install and tighten [3x] - Fastener Specifications
- Charge Air Cooler Bracket - Install
Install the high pressure diesel fuel injection rail (1).
Fuel Injection Fuel Rail Nut (1) - Install and tighten [3x] - Fastener Specifications
Install and connect the glow plug wiring harness (1).
- Attach the wiring harness retainers to the intake manifold.
Intake Air Pressure and Temperature Sensor (2) - Install
- Intake Air Pressure and Temperature Sensor Bolt (1) - Install and tighten - Fastener Specifications
If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps:
- Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
- Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Exhaust Manifold Gasket (1) - Install NEW
- Exhaust Manifold (2) - Install
- Exhaust Manifold Flange Bolt (3) - Install and hand tighten [12x]
- Exhaust Manifold Flange Bolt (3) - Tighten in sequence [12x] - Fastener Specifications
Exhaust Manifold Heat Shield (1) Install
- Exhaust Manifold Heat Shield Bolt (2) - Install and tighten - Fastener Specifications
-
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
Turbocharger Coolant Feed and Return Pipe Gasket (1) - Install NEW [2x]
Engine Coolant Air Bleed Hose (3) - Install
- Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
- Engine Coolant Air Bleed Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Install the wiring harness.
- NOTE:
Some components not shown for graphic clarity.
Wiring Harness Retainer (3) @ Engine Coolant Air Bleed Hose - Install [2x]
Exhaust Gas Recirculation Valve Inlet Gasket (3) - Install NEW
- Install the exhaust gas recirculation valve (2) and exhaust gas recirculation cooler inlet pipe as an assembly.
- Exhaust Gas Recirculation Valve Bolt (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Gas Recirculation Valve Bracket Nut (1) - 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
Secure the EN-52446-3 Base (1) in a vice.
- Install the 4 EN-52446-4 Studs (3) in base.
- Place the timing chain lower cover (2) outward facing side up on the base.
- Install the EN-52446-2 Seal Protector (4) onto the EN-52446-3 Base (1).
- Install a NEW crankshaft rear oil seal (5) to the EN-52446-3 Base (1), using the EN-52446-2 Seal Protector (4) to center the crankshaft rear oil seal (5).
- Remove the EN-52446-2 Seal Protector (4).
Install the EN-52446-1 Installer (1) on the crankshaft rear oil seal (4).
- Install 4 washers (2) onto the EN-52446-4 Studs.
- Install the 4 EN-52446-5 Nuts (3) onto the studs.
- Hand tighten the 4 EN-52446-5 Nuts (3) evenly until the crankshaft rear oil seal (4) is fully seated in the cover.
- Remove the EN-52446 Assembly from the crankshaft rear oil seal (4).
- NOTE:
If service part comes with seal protector then use inner seal protector ring to slip the seal lip over the crankshaft snout, instead of EN-52446-2 Seal Protector.
Install the EN-52446-2 Seal Protector (1) to the crankshaft.
- Install the 4 EN-52446-4 Studs (2).
- Install the 4 EN-52446-5 Nuts (3) and hand tighten.
- NOTE:
- Observe the locations for additional sealer (2) while applying the sealant path.
- The bolts must be installed and fastened to final torque specification immediately after the component is installed.
Clean all sealing surfaces.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Apply a 4.0 mm (0.158 in) bead of sealer along the timing chain lower cover sealing path (1), dimension a. Increase the bead to 6.0 mm (0.236 in) at the two locations (2), dimension b. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
If service part comes with seal protector then use inner seal protector ring to slip the seal lip over the crankshaft snout, instead of EN-52446-2 Seal Protector.
Align the timing chain lower cover (1) with the two transmission locating pins (2).
- Timing Chain Lower Cover (1) - Install
- Check that the crankshaft rear oil seal sits correct on the crankshaft.
- Remove the EN-52446-2 Seal Protector (3).
Timing Chain Cover Bolt (1) - Install and hand tighten
- Timing Chain Cover Bolt (2) - Install and hand tighten [15x]
- Timing Chain Cover Bolt - Tighten in sequence [16x] - Fastener Specifications
Install 6 NEW fuel injector seal rings (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 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
Fuel Injector Fuel Return Hose Bracket (2) - Install
- Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Install and tighten [2x] - 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
Automatic Transmission Flex Plate (1) - Install
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Automatic Transmission Flex Plate Bolt (2) - Install NEW and hand tighten [8x]
- Automatic Transmission Flex Plate Bolt (2) - Tighten in sequence [8x] - Fastener Specifications
Remove the EN-49979 Holder (1) with EN-956-1 Extension (3).
- Install the EN-52474 Engine Lift Bracket Set.
- Using a suitable engine lifting device, remove the engine from the engine stand.
EN-52449 Engine Stand Adapter (2) @ Engine Block - Remove
- Engine - Install - Engine Removal and Installation (4WD, with RC1, without F47) , or Engine Removal and Installation (2WD, with RC1, without F47) , or 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)
Once the EN-52586 Crankshaft Fixing Pin is installed, do not remove until all timing components have been installed.
Observe the markings on the bearing caps. Each bearing cap has an identification number. Ensure that the identification number in the bearing caps is in line with the corresponding identification number on the ladder frame.
Observe the markings on the bearing caps. Each bearing cap has an identification number. Ensure that the identification number in the bearing caps is in line with the corresponding identification number on the ladder frame.
Ensure the 2 cylinder head locating pins (3) are properly seated in the engine block.
Refer to Torque-to-Yield Fastener Caution .
Refer to Fastener Caution .
Final torque for camshaft sprockets is completed after secondary timing chain and exhaust camshaft sprocket is installed.
Take note that there are different bolt lengths.
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.