LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2023 >> Tahoe SSV >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 17 (Engine Mechanical - 3.0L (Lm2) Diesel - Repair Instructions (4 Of 11)) >> Repair Instructions >> Crankshaft and Bearing Removal and Installation >> Assemble Procedure

Assemble Procedure

WARNING: This page is about a different variant/trim than selected.
  1. GM5148478Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Ensure that the guide lugs (3) are seated properly.
    • When using the original crankshaft bearing, ensure it is installed in the same position as removed.

    Lubricate the crankshaft upper bearings with engine oil. Adhesives, Fluids, Lubricants, and Sealers

  2. Install the 2 crankshaft thrust bearings (2).
  3. GM5148482Courtesy of GENERAL MOTORS COMPANY

    Lubricate the crankshaft with engine oil. Adhesives, Fluids, Lubricants, and Sealers

  4. Crankshaft (1) - Install
  5. GM5148487Courtesy of GENERAL MOTORS COMPANY

    Check the 2 crankshaft thrust bearings (1) for proper seat.

  6. GM5148474Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Ensure that the guide lugs (2) are seated properly.
    • When using the original crankshaft bearing, ensure it is installed in the same position as removed.

    Lubricate the crankshaft lower bearings with engine oil. Adhesives, Fluids, Lubricants, and Sealers

  7. Crankshaft Lower Bearing (1) @Crankshaft Bearing Cap (3) - Install [7x]
  8. GM5148472Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • When using the original crankshaft bearing cap, ensure it is installed in the same position as removed.
    • The arrow (3) on the crankshaft bearing cap must shown in the front direction of the engine.

    Crankshaft Bearing Cap (2) - Install [7x]

  9. Crankshaft Bearing Cap Bolt (1) - Install NEW [14x] - Fastener Specifications
  10. Coat the following components with engine oil:
    • Connecting rods
    • Connecting rod bearings
  11. GM5148430Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • If the old connecting rod bearing caps will be reused, install in the original position.
    • If the old bearing will be reused, install in the original position.
    • Ensure that the connecting rod marks (4) are oriented toward rear of engine.

    Install the 2 connecting rod bearing caps (2) along with the 2 connecting rod bearings (1) on the connecting rods at cylinder 2 and cylinder 5. Fastener Specifications

  12. Turn the crankshaft 120 degrees.
  13. GM5148436Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • If the old connecting rod bearing caps will be reused, install in their original position.
    • If the old bearing will be reused, install in the original position.
    • Ensure that the connecting rod marks (4) are oriented toward rear of engine.

    Install the 2 connecting rod bearing caps (3, 6) along with the 2 connecting rod bearings (1, 2) on the connecting rods at cylinder 3 and cylinder 4. Fastener Specifications

    14. NOTE:

    Ensure that the sealing surface is clear of oil, grease and old sealant material.

  14. Clean all sealing surfaces.
  15. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  16. GM5148170Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Install and align the lower crankcase extension to the engine block within 8 minutes after applying the sealer.
    • The bolts must be installed and fastened to final torque specification immediately after the component is installed.

    Apply a 4 mm (0.158 in) bead of sealer (1) along the perimeter of the sealing surface and at the center location, dimension a. Adhesives, Fluids, Lubricants, and Sealers

  17. Apply a 6 mm (0.236 in) bead of sealer (2) at 4 locations on each end of the perimeter sealing surface, dimension b. Adhesives, Fluids, Lubricants, and Sealers
  18. GM5148171Courtesy of GENERAL MOTORS COMPANY

    Oil Pump Gasket (5) - Install NEW

  19. Upper Oil Pan Gasket (4) - Install NEW
    20. NOTE:

    Check that the 2 guide pins (1, 3) from the lower crankcase extension sit correctly in the engine block.

  20. Lower Crankcase Extension (2) - Install
  21. GM5148168Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Install all lower crankcase extension bolts hand tight only prior to the tightening sequence.

    Lower Crankcase Extension Bolt - M8 (4) - Install NEW [7x]

    22. NOTE:

    Take note that there are different bolt lengths.

  22. Lower Crankcase Extension Bolt - M6 (1, 2, 3) - Install and hand tighten [14x]
  23. Lower Crankcase Extension Bolt - M6 (1, 2, 3) - Tighten in sequence [14x] - Fastener Specifications
  24. GM5148147Courtesy of GENERAL MOTORS COMPANY

    Oil Pump Gasket (2, 5) - Install NEW [2x]

    25. NOTE:

    Ensure that the pump shaft coupling is aligned vertically, parallel with the oil pump bolts.

  25. Oil Pump (1) - Install
  26. Check that the oil pump drive gear (3) sits correct in the oil pump drive shaft (4).
  27. GM5208401Courtesy of GENERAL MOTORS COMPANY

    Oil Pump Bolt (1) - Install and hand tighten [4x]

  28. GM5208387Courtesy of GENERAL MOTORS COMPANY

    Connect the electrical connector. (1)

  29. GM5148148Courtesy of GENERAL MOTORS COMPANY

    Oil Pump Bolt (1) - Tighten in sequence [4x] - Fastener Specifications

    30. NOTE:

    Ensure that the sealing surface is clear of oil, grease and old sealant material.

  30. Clean all sealing surfaces.
  31. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  32. GM5145853Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Install and align the oil pan to the lower crankcase extension within 8 minutes after applying the sealer.
    • The bolts must be installed and fastened to final torque specification immediately after the component is installed.

    Apply a 4.0 mm (0.158 in) bead of sealer (1) to the oil pan sealing surface. Adhesives, Fluids, Lubricants, and Sealers

  33. GM5145857Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Ensure the alignment pins (2, 3) are properly aligned when installing the oil pan.

    Lower Oil Pan (1) - Install NEW

  34. GM5654970Courtesy of GENERAL MOTORS COMPANY

    Oil Pan Bolt (1) - Install and tighten [23x] - Fastener Specifications

    35. 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:

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

  35. Clean all sealing surfaces.
  36. GM5147858Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Guide (1) - Install

  37. GM5871991Courtesy of GENERAL MOTORS COMPANY

    Install the timing chain (1) to the fuel injection pump driven sprocket (2).

  38. Lubricate the high pressure diesel fuel pump shaft. Adhesives, Fluids, Lubricants, and Sealers
  39. GM5871961Courtesy of GENERAL MOTORS COMPANY

    Install the timing chain (1) and the fuel injection pump driven sprocket (2) as an assembly.

  40. GM5150342Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Guide (1) - Install

  41. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
    42. CAUTION:

    Refer to Fastener Caution .

  42. Timing Chain Guide Bolt (2) - Install and tighten [2x] - Fastener Specifications
  43. GM5318516Courtesy of GENERAL MOTORS COMPANY

    Observe the alignment of the timing links on the timing chain for installation:

    • Timing link (1) will align with the fuel injection pump driven sprocket
    • Timing link (2) will align with the primary timing chain fixed guide
    • Timing link (3) will align at the lower position at the crankshaft sprocket
    44. NOTE:

    The link at the crankshaft is difficult to see.

  44. If the 3 color links are not aligned, rotate the fuel injection pump shaft until alignment is achieved.
  45. GM5872021Courtesy of GENERAL MOTORS COMPANY

    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:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  46. Install a NEW fuel injection pump bolt (1) and hand tighten.
  47. GM5147443Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Guide (1) - Install

  48. 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:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  49. Timing Chain Guide Bolt (2) - Install and tighten - Fastener Specifications
  50. GM5146080Courtesy of GENERAL MOTORS COMPANY

    Secondary Timing Chain (1) - Install

  51. Ensure that the timing chain slack is on the secondary timing chain tensioner side.
  52. GM5147541Courtesy of GENERAL MOTORS COMPANY

    Camshaft Sprocket (2) - Install

  53. Camshaft Position Sensor Exciter Wheel (1) - Install
  54. Camshaft Sprocket Bolt (3) - Install NEW and hand tighten
  55. GM5239053Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Guide (1) - Install

    1. 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:
    2. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    3. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    4. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    5. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  56. Timing Chain Guide Bolt (2) - Install and tighten [2x] - Fastener Specifications
  57. GM5145520Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Position Sensor Seal (1) - Install NEW

  58. Crankshaft Position Sensor (2) - Install
  59. Crankshaft Position Sensor Bolt (3) - Install and tighten - Fastener Specifications
  60. GM5147521Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Check that the nose of the EN-52445-3  Camshaft Tool (1) 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.

  61. GM5147524Courtesy of GENERAL MOTORS COMPANY

    Camshaft Sprocket Bolt (1) - Tighten - Fastener Specifications

  62. GM5237886Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Tensioner (4) - Install

  63. Timing Chain Tensioner Bolt (3) - Install and tighten [2x] - Fastener Specifications
  64. GM5146036Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Tensioner Gasket (1) - Install NEW

    65. CAUTION:

    Refer to Component Fastener Tightening Caution .

  65. Timing Chain Tensioner (2) - Install and tighten - Fastener Specifications
  66. Remove the EN-52234  Timing Chain Tensioner Retaining Pin (2).
  67. GM5872021Courtesy of GENERAL MOTORS COMPANY

    Tighten the fuel injection pump bolt (1). Fastener Specifications

  68. GM5145487Courtesy of GENERAL MOTORS COMPANY

    Timing Belt (1) @Oil Pump Sprocket (2) - Install

  69. Timing Belt (1) @Crankshaft - Install
  70. Oil Pump Sprocket (2) - Install
  71. GM5145486Courtesy of GENERAL MOTORS COMPANY

    Install the EN-47634  Holder (1) to the oil pump sprocket (2).

  72. Oil Pump Drive Bolt (3) - Install and tighten - Fastener Specifications
  73. Remove the EN-47634  Holder (1) and the EN-956  Extension (4).
  74. GM5140935Courtesy of GENERAL MOTORS COMPANY

    Lubricate the 24 hydraulic valve lash adjusters and valve rocker arms with engine oil. Adhesives, Fluids, Lubricants, and Sealers

  75. Valve Rocker Arm (1) @Hydraulic Valve Lash Adjuster (2) - Install [24x]
  76. GM5140933Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Used valve rocker arms must be returned to the original position on the camshaft. If the camshaft is being replaced, the lash adjuster arms actuated by the camshaft must also be replaced.

    Install the 24 valve rocker arms (1) and the 24 hydraulic valve Lash adjuster (2).

  77. GM5147734Courtesy of GENERAL MOTORS COMPANY

    Install the EN-52445-1  Camshaft Tool (3) to the.

  78. Check that the tab (1) of the EN-52445-1  Camshaft Tool sits correctly under the camshaft bearing rear cap (2).
  79. Check that the 2 pins (6) of the EN-52445-1  Camshaft Tool sit correctly in the 2 camshafts.
  80. GM5147733Courtesy of GENERAL MOTORS COMPANY

    Align the 2 camshaft notchs (5) with the arrow on the camshaft bearing rear cap (4).

  81. Install the EN-52445-2  Camshaft Tool (1, 2, 3) to the camshafts.
  82. GM5147735Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The gasket (2) has four attached seal rings and is different than the other five gaskets (1), that have three attached seal rings. Ensure all gaskets are installed in the correct orientation, with the tab (3) fitting into the housing slot (4).

    Camshaft Housing Gasket (1) - Install NEW [5x]

  83. Camshaft Housing Gasket (2) - Install NEW
  84. GM5147736Courtesy of GENERAL MOTORS COMPANY

    Camshaft Housing (1) - Install

  85. Ensure that the is positioned correctly on the 2 cover locating pins (3, 4).
  86. Install and hand tighten the 6 bolts (2) of the EN-52445-1  Camshaft Tool.
  87. Fig 1: Camshaft Tool And Bolts With Tightening Sequence
    GM5147732Courtesy of GENERAL MOTORS COMPANY

    Hand tighten the 6 bolts (1) of the EN-52445-1  Camshaft Tool 1/2 turn in sequence as shown, until the is flush with the cylinder head.

  88. GM5147737Courtesy of GENERAL MOTORS COMPANY

    Camshaft Housing Bolt (1) - Install [16x]

  89. Camshaft Housing Bolt (1) - Tighten in sequence [16x] - Fastener Specifications
  90. GM5147738Courtesy of GENERAL MOTORS COMPANY

    Check the correct seat of the 6 gaskets (1). The seal tab must not be displaced.

  91. GM5146210Courtesy of GENERAL MOTORS COMPANY

    Remove EN-52445-2  Camshaft Tool (1, 2).

  92. GM5146041Courtesy of GENERAL MOTORS COMPANY

    Remove the 6 bolts (2) from EN-52445-1  Camshaft Tool Holder

  93. Remove EN-52445-1  Camshaft Tool Holder (1).
  94. GM5146210Courtesy of GENERAL MOTORS COMPANY

    Install the EN-52445-2  Camshaft Tool (1, 2).

  95. GM5146206Courtesy of GENERAL MOTORS COMPANY

    Camshaft Sprocket (2) - Install

    96. NOTE:

    Final torque for camshaft sprockets is completed after secondary timing chain and exhaust camshaft sprocket is installed.

  96. Camshaft Sprocket Bolt (1) - Install NEW and hand tighten
  97. GM5146078Courtesy of GENERAL MOTORS COMPANY

    Check that the EN-52586  Crankshaft Fixing Pin (1) is still installed.

  98. GM5146079Courtesy of GENERAL MOTORS COMPANY

    Check that the first color link (1) on the timing chain is aligned with the arrow on the fuel injection pump driven sprocket (2) and the second color link (3) is aligned with the window of the timing chain guide (4).

  99. If the 2 color links are not aligned, remove any components necessary and align the timing chain again.
  100. GM5238670Courtesy of GENERAL MOTORS COMPANY

    Remove EN-52234  Timing Chain Tensioner Retaining Pins (1).

  101. GM5146037Courtesy of GENERAL MOTORS COMPANY

    Remove EN-52445-3  Camshaft Tool Holder (2).

  102. Remove EN-52445-2  Camshaft Tool Holder (1, 3)
  103. GM5214756Courtesy of GENERAL MOTORS COMPANY

    EN-52586  Crankshaft Fixing Pin (4) - Remove

  104. Rotate the engine by hand to ensure there is no interference.
  105. Crankshaft Pulley Bolt (1) - Remove [4x]
  106. GM5766443Courtesy of GENERAL MOTORS COMPANY

    Secure the EN-52446-3  Base (1) in a vice.

  107. Install the 4 EN-52446-4  Studs (3) in base.
  108. Place the timing chain lower cover (2) outward facing side up on the base.
  109. Install EN-52446-2  Seal Protector (4) onto the EN-52446-3  Base (1).
  110. Install 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).
  111. Remove the EN-52446-2  Seal Protector (4).
  112. GM5766445Courtesy of GENERAL MOTORS COMPANY

    Install the EN-52446-1  Installer (1) on the crankshaft rear oil seal (4).

  113. Install 4 washers (2) onto the EN-52446-4  Studs.
  114. Install the 4 EN-52446-5  Nuts (3) onto the studs.
  115. Tighten the 4 EN-52446-5  Nuts (3) evenly until the crankshaft rear oil seal (4) is fully seated in the cover.
  116. Remove the EN-52446  Assembly from the crankshaft rear oil seal (4).
  117. GM5145916Courtesy of GENERAL MOTORS COMPANY
    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.

  118. Install the 4 EN-52446-4  Studs (2).
  119. Install the 4 EN-52446-5  Nuts (3) and hand tighten.
  120. GM5145915Courtesy of GENERAL MOTORS COMPANY
    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.

  121. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  122. 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
  123. GM5145917Courtesy of GENERAL MOTORS COMPANY
    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).

  124. Timing Chain Lower Cover (1) - Install
  125. Check that the crankshaft rear oil seal sits correct on the crankshaft.
  126. Remove the EN-52446-2  Seal Protector (3).
  127. GM5145918Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Cover Bolt (1, 2) - Install and tighten - Fastener Specifications

    128. NOTE:

    Ensure that the sealing surface is clear of oil, grease and old sealant material.

  128. Clean all sealing surfaces.
  129. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  130. GM5138713Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Observe the locations for additional sealer while applying the sealant path.
    • Install and align the timing chain upper cover to the cylinder head within 8 minutes after applying the sealer.
    • 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

    1. Begin applying a 6.0 mm (0.236 in) bead, dimension a, as shown.
    2. 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.
    3. At the end of the bead path, increase to a 6.0 mm (0.236 in) bead, dimension a, as shown.
  131. GM5138708Courtesy of GENERAL MOTORS COMPANY

    Engine Front Cover Locating Pin (2) @Cylinder Head - Install [2x]

  132. Timing Chain Upper Cover (1) @Cylinder Head - Install
    133. NOTE:

    Take note that there are different bolt lengths.

  133. Apply sealant to the front threads of the 2 timing chain cover bolts (4).
  134. Timing Chain Cover Bolt (3, 4) - Install and tighten [6x] - Fastener Specifications
  135. Clean off the excess sealant residue between the timing chain upper cover and the cylinder head.
  136. Clean the glow plugs and mating hole, it must be free of lubricant and grease.
  137. GM5138598Courtesy of GENERAL MOTORS COMPANY
    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 NEW and tighten [6x] - Fastener Specifications

  138. GM5239643Courtesy of GENERAL MOTORS COMPANY

    Clean the camshaft housing gasket surface on the cylinder head.

  139. If the camshaft housing is reused, clean the camshaft housing seal groove.
  140. Camshaft Housing Gasket (1) @Camshaft Housing - Install NEW [2x]
  141. GM5138528Courtesy of GENERAL MOTORS COMPANY

    Inspect each of the 26 camshaft housing bolts (2) in the camshaft housing (4). Ensure the correct seat of the 26 camshaft housing bolt bushings (3) and the camshaft housing cover insulator (1) with the camshaft housing gasket (5).

  142. GM5247644Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Install and align the camshaft housing to the cylinder head within 8 minutes after applying the sealer.
    • 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 camshaft housing sealing locations where the timing chain upper cover joins the cylinder head. Adhesives, Fluids, Lubricants, and Sealers

  143. GM5239647Courtesy of GENERAL MOTORS COMPANY

    Camshaft Housing (1) @Cylinder Head - Install

  144. Camshaft Housing Bolt (2) - Install and tighten [26x] - Fastener Specifications
  145. GM5136923Courtesy of GENERAL MOTORS COMPANY

    Clean the 6 fuel injector bores in the cylinder head.

  146. If the fuel injector is reused, clean the fuel injectors.
  147. Fuel Injector Seal (2) - Install NEW [6x]
  148. Fuel Injector Washer (3) - Install NEW [6x]
  149. High Pressure Diesel Fuel Injector (1) - Install [6x]
  150. GM5136920Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Pay attention to the mounting position of the injector brackets.

    Multiport Fuel Injector Bracket (2) - Install [6x]

    151. NOTE:

    Tighten the fuel injector bracket bolt only when installing the high pressure diesel fuel feed pipes.

  151. Fuel Injector Bolt (1) - Install, but do NOT tighten [6x]
  152. GM5138666Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Bracket (1) - Install

  153. High Pressure Diesel Fuel Injection Rail (2) - Install
    154. NOTE:

    Tighten the fuel injection fuel rail nuts only when installing the high pressure diesel fuel feed pipes.

  154. Fuel Injection Fuel Rail Nut (3) - Install, but do NOT tighten [3x]
  155. GM5138665Courtesy of GENERAL MOTORS COMPANY

    Diesel Glow Plug Wiring Harness (3) - Install

  156. Electrical Connector (2) @Glow Plug - Connect [6x]
  157. Clip (1) @Diesel Glow Plug Wiring Harness - Install [3x]
  158. GM5138465Courtesy of GENERAL MOTORS COMPANY

    High Pressure Diesel Fuel Feed to Injector Pipe (2) - Install [3x]

    1. Hand tighten the NEW 3 gray coded high pressure diesel fuel feed pipes nuts (3) at the fuel rail.
    2. Hand tighten the NEW 3 black coded high pressure diesel fuel feed pipes nuts (5) at the fuel injector.
  159. High Pressure Diesel Fuel Feed to Injector Pipe (1) - Install [3x]
    1. Hand tighten the NEW 3 gray coded high pressure diesel fuel feed pipes nuts (3) at the fuel rail.
    2. Hand tighten the NEW 3 black coded high pressure diesel fuel feed pipes nuts (5) at the fuel injector.
  160. Fuel Injector Bolt (4) @Multiport Fuel Injector Bracket - Tighten [6x] - Fastener Specifications
  161. Tighten the 6 gray coded high pressure diesel fuel feed pipes nuts (3) at the fuel rail. Fastener Specifications
  162. Tighten the 6 black coded high pressure diesel fuel feed pipes nuts (5) at the fuel injector. Fastener Specifications
  163. GM5138462Courtesy of GENERAL MOTORS COMPANY

    Fuel Injection Fuel Feed Pipe Bracket (1) - Install

  164. Fuel Injection Fuel Feed and Return Pipe Retainer Bolt (2) - Install and tighten - Fastener Specifications
  165. GM5214969Courtesy of GENERAL MOTORS COMPANY

    Fuel Injector Fuel Return Hose Bracket (2) - Install

  166. Fuel Return Pipe Clip Bolt (1) - Install and tighten [2x] - Fastener Specifications
  167. GM5138370Courtesy of GENERAL MOTORS COMPANY

    High Pressure Diesel Fuel Feed to Rail Pipe (1) - Install NEW [2x]

    1. Hand tighten the 2 high pressure diesel fuel feed to rail pipes to the fuel injection fuel rail (5).
    2. Hand tighten the 2 high pressure diesel fuel feed to rail pipes to the fuel injection fuel pump (4).
  168. Fuel Feed Pipe Clip Bolt (2, 3) - Install and tighten [4x] - Fastener Specifications
  169. High Pressure Diesel Fuel Feed to Rail Pipe (1) - Install and tighten [4x] - Fastener Specifications
  170. GM5239993Courtesy of GENERAL MOTORS COMPANY

    Fuel Injection Fuel Rail Nut (1) - Tighten [3x] - Fastener Specifications

  171. GM5138304Courtesy of GENERAL MOTORS COMPANY

    Fuel Pump Fuel Feed Hose (2) - Install

  172. Fuel Feed Hose Connector (4) - Connect - Metal Collar Quick Connect Fitting Service
  173. Fuel Feed Hose Connector Retainer (3) Engage
  174. Heater Outlet Pipe Bolt (1) @Fuel Pump Fuel Feed Hose - Install and tighten - Fastener Specifications
  175. GM5138258Courtesy of GENERAL MOTORS COMPANY

    Seal Ring (6) - Install NEW [6x]

  176. Fuel Injection Fuel Return Pipe (2) - Install
  177. Clip the fuel injection fuel pipe retainer (3) to the high pressure diesel fuel feed to rail pipe.
  178. Push the 6 fuel injection fuel return pipe locking springs (1) in the direction shown and install the fuel injection fuel return pipe on the fuel injectors.
  179. Fuel Injection Fuel Return Pipe Clip (4) @High Pressure Diesel Fuel Injection Rail - Install
  180. Unlock the fuel injection fuel return pipe clip (5) by pressing the spring notch in direction of the arrow, and install the hose to the diesel fuel separator.
  181. GM5214815Courtesy of GENERAL MOTORS COMPANY

    Fuel Injector Wiring Harness (3) - Install

  182. Retaining Clip (2) @Fuel Injector Wiring Harness - Install [8x]
  183. Wiring Harness Connector (1) @Fuel Injector Wiring Harness - Connect [6x]
  184. GM5214756Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Pulley Bolt (1) - Install [4x]

  185. Rotate the crankshaft with a suitable tool in the direction of the arrow at the crankshaft pulley bolts (1), until the crankshaft locking divot (2) aligns with the engine block (3).
  186. EN-52586  Crankshaft Fixing Pin (4) - Install
  187. GM5133553Courtesy of GENERAL MOTORS COMPANY

    Clean the 8 flex plate bolt threads in the crankshaft.

    188. NOTE:

    The flex plate and the bolts fits only in one position.

  188. Position the flex plate (1) to align the flex plate alignment bore (2) to the crankshaft alignment bore.
  189. GM5133550Courtesy of GENERAL MOTORS COMPANY

    Automatic Transmission Flex Plate (1) - Install

  190. Due to the unknown shelf life of the adhesive patch, prepare the 8 NEW automatic transmission flex plate bolts (2) as follows:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  191. Automatic Transmission Flex Plate Bolt (2) - Install NEW and hand tighten [8x]
  192. EN-52586  Crankshaft Fixing Pin - Remove
  193. Clean all sealing surfaces.
  194. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  195. GM5148269Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Observe the locations for additional sealer while applying the sealant path.
    • Install and align the crankshaft front oil seal to the block within 8 minutes after applying the sealer.
    • The bolts must be installed and fastened to final torque specification immediately after the component is installed.

    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

  196. GM5148273Courtesy of GENERAL MOTORS COMPANY

    Install the EN-52452  Front Crankshaft Seal Installer (1).

  197. Install and hand tighten 2 bolts EN-52452  Front Crankshaft Seal Installer (2).
  198. GM5148276Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Front Oil Seal (1) - Install NEW

  199. Check that the crankshaft front oil seal sits correct on the crankshaft and on the engine front cover locating pins (2, 4)
  200. Remove the 2 bolts from the EN-52452  Front Crankshaft Seal Installer (5)
  201. Remove the EN-52452  Front Crankshaft Seal Installer (3).
  202. GM5148278Courtesy of GENERAL MOTORS COMPANY

    Engine Front Cover Bolt (1) - Install and tighten [8x] - Fastener Specifications

  203. GM5137217Courtesy of GENERAL MOTORS COMPANY

    Radiator Outlet Pipe Seal (2) @Water Pump Inlet Pipe (1) - Install NEW

  204. Water Pump Inlet Pipe (1) @Engine Block - Install
  205. Water Pump Gasket (3) @Water Pump (4) - Install NEW
  206. Water Pump (4) - Install
  207. Water Pump Bolt (5, 6) - Install and tighten [6x] - Fastener Specifications
  208. GM5137111Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Pulley (1) - Install

  209. Crankshaft Pulley Bolt (2) - Install, but do NOT tighten [4x]
  210. GM5137110Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Have an additional technician hold the special tool EN-956-1  Extension in place while torquing takes place.

    Install the EN-49979  Holder (1) with EN-956-1  Extension (3).

  211. Crankshaft Pulley Bolt (2) - Tighten - Fastener Specifications
  212. Remove the EN-49979  Holder (1) with EN-956-1  Extension (3).
  213. GM5136940Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Thermostat Housing Gasket (1) - Install NEW

  214. Engine Coolant Flow Control Valve (2) - Install
  215. Engine Coolant Flow Control Valve Bolt (3) Install and tighten [6x] - Fastener Specifications
  216. GM5206143Courtesy of GENERAL MOTORS COMPANY

    Engine Oil Cooler Gasket (3) - Install NEW

  217. Engine Oil Cooler Gasket (2) - Install NEW
  218. Engine Oil Cooler (1) - Install
  219. GM5206140Courtesy of GENERAL MOTORS COMPANY

    Engine Oil Cooler Bolt (1) - Install and tighten [5x] - Fastener Specifications

  220. GM5136785Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Runner Control Valve Gasket (3) - Install NEW

  221. Intake Manifold (1) - Install
  222. Intake Manifold Bolt (2) - Install [9x] - Fastener Specifications
  223. GM5136780Courtesy of GENERAL MOTORS COMPANY
    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

  224. Intake Manifold Cover Retainer (2) - Install [2x]
  225. GM5136778Courtesy of GENERAL MOTORS COMPANY

    Diesel Glow Plug Wiring Harness (1) @Intake Manifold - Install

  226. GM5633617Courtesy of GENERAL MOTORS COMPANY

    Clean the exhaust manifold flange bolt threads in the cylinder head.

  227. Exhaust Manifold Gasket (3) - Install NEW
  228. Exhaust Manifold (2) - Install
  229. Exhaust Manifold Flange Bolt (1) - Install and tighten [12x] - Fastener Specifications
  230. GM5626993Courtesy of GENERAL MOTORS COMPANY

    Exhaust Manifold Heat ShieldInstall

  231. Exhaust Manifold Heat Shield Bolt (1) - Install - Fastener Specifications
  232. GM5136702Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Oil Return Pipe Gasket (5) - Install NEW

  233. Turbocharger Oil Feed Pipe Gasket (6) - Install NEW
  234. Turbocharger Gasket (3) - Install NEW
  235. Turbocharger Assembly (1) - Install
  236. Turbocharger Nut (2, 4) - Install NEW [3x]
  237. Turbocharger Oil Return Pipe Bolt (8) - Install and tighten [2x] - Fastener Specifications
  238. Turbocharger Oil Feed Pipe Bolt (7) - Install and tighten [2x] - Fastener Specifications
  239. Turbocharger Oil Feed Pipe Bracket Bolt (9) - Install and tighten - Fastener Specifications
  240. Turbocharger Nut (2, 4) - Tighten [3x] - Fastener Specifications
  241. GM5210041Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Valve Cooling Feed Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type

  242. Exhaust Gas Recirculation Valve Cooling Feed Hose (2) - Install
  243. GM5135103Courtesy of GENERAL MOTORS COMPANY

    Positive Crankcase Ventilation Hose Clamp (1) - Release [2x] - Hose Clamp Replacement Guidelines - Spring Type

  244. Positive Crankcase Ventilation Hose (2) - Install
  245. GM5135048Courtesy of GENERAL MOTORS COMPANY

    Oil Level Indicator Seal (2) @Oil Level Indicator Tube - Install NEW

  246. Oil Level Indicator Tube (1) - Install
  247. GM5135046Courtesy of GENERAL MOTORS COMPANY

    Oil Level Indicator Tube Bolt (3) - Install and tighten [2x] - Fastener Specifications

  248. Clip (4) @Oil Level Indicator Tube - Install
  249. Engine Oil Level Indicator (2) - Install
  250. GM5208673Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install NEW

  251. Exhaust Gas Recirculation Cooler Inlet Pipe (2) - Install
    252. NOTE:

    Support the exhaust gas recirculation cooler inlet pipe when applying torque to the bolts.

    NOTE:

    Considering the reduced clearance, carefully install the bolts to ensure the tool does not contact the pipe.

  252. Exhaust Gas Recirculation Cooler Bolt (1) - Install and tighten [2x] - Fastener Specifications
  253. GM5138657Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Air Bleed Hose (1) - Install

  254. Engine Coolant Outlet Pipe Bracket Bolt (2) - Install and tighten - Fastener Specifications
  255. GM5609033Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Coolant Feed and Return Pipe Gasket (1) - Install NEW [2x]

  256. GM5203915Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Some components not shown for graphic clarity.

    Engine Coolant Air Bleed Hose (3) - Install

  257. Engine Coolant Air Bleed Hose Stud (2) - Install and tighten - Fastener Specifications
  258. Engine Coolant Air Bleed Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
  259. GM5203904Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Some components not shown for graphic clarity.

    Wiring Harness Retainer (3) @Engine Coolant Air Bleed Hose - Install [2x]

  260. Engine Coolant Air Bleed Hose (2) @Engine Coolant Air Bleed Hose - Install
  261. Engine Coolant Air Bleed Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  262. GM5203874Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Some components not shown for graphic clarity.

    Position the engine wiring harness channel (3) to the front of the engine.

  263. Engine Wiring Harness Bracket Bolt (2) - Install and tighten - Fastener Specifications
  264. Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  265. GM5134476Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Air Bleed Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type

  266. Engine Coolant Air Bleed Pipe (2) - Install
  267. Clip (3) @Exhaust Gas Recirculation Cooler Outlet Pipe - Engage
  268. GM5134446Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Thermostat Gasket (1, 6) @Thermostat Bypass Hose - Install NEW [2x]

  269. Thermostat Bypass Hose (3) - Install
  270. Thermostat Bypass Pipe Bolt (2, 5) - Install and tighten [4x] - Fastener Specifications
  271. Thermostat Bypass Pipe Bolt (4) - Install and tighten - Fastener Specifications
  272. GM5134389Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Thermostat Gasket (4) @Thermostat Bypass Hose - Install NEW

  273. Thermostat Bypass Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type
  274. Thermostat Bypass Hose (2) - Install
  275. Thermostat Bypass Pipe Bolt (3) - Install and tighten [2x] - Fastener Specifications
  276. GM5485237Courtesy of GENERAL MOTORS COMPANY

    Thermostat Bypass Hose Clamp (3) - Release - Hose Clamp Replacement Guidelines - Spring Type

  277. Thermostat Bypass Hose (1) - Install
  278. Water Outlet Stud (2) - Install and tighten - Fastener Specifications
  279. GM5615569Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Coat the oil filter seal with a thin film of fresh engine oil.

    Oil Filter (3) - Install and tighten - 3/4 to 1 full turn after gasket makes contact with the sealing surface on the filter mounting flange

  280. Clean and inspect the oil pan drain plug (1) and seal (2). Replace as necessary.
  281. Oil Pan Drain Plug Seal (2) - Install
  282. Oil Pan Drain Plug (1) - Install and tighten - Fastener Specifications
  283. GM5139662Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Engine prelubing is necessary by using a NEW engine block.

    If equipped, remove the engine oil pressure sensor thread hole closure plug instead of the engine oil pressure sensor (1).

  284. Engine Oil Pressure Sensor - Remove and DISCARD
  285. Install the M12x1.75 adapter P/N 509376.
  286. GM863255Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    A constant and continuous flow of clean engine oil is required in order to properly prime the engine. Ensure an approved engine oil is used, as specified in the owners manual.

    Install the flexible hose to the adapter and open the valve.

  287. Pump the handle on the EN-45299  Engine Preluber in order to flow a minimum of 1 - 1.9 liters (1 - 2 quarts) of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
  288. Close the valve and remove the flexible hose and adapter from the engine.
  289. Engine Oil Pressure Sensor - Install NEW and hand tighten - Fastener Specifications
  290. Fill the engine oil to the proper level with NEW engine oil.
  291. Install the EN-52474  Engine Lift Hook Set.
  292. 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)
scientia non olet · About LEMON Manuals