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Home >> Chevrolet >> 2023 >> Tahoe SSV >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 19 (Engine Mechanical - 3.0L (Lm2) Diesel - Repair Instructions (11 Of 11)) >> Repair Instructions >> Engine Block Overhaul >> Assemble Procedure

Assemble Procedure

WARNING: This page is about a different variant/trim than selected.
  1. GM5148959Courtesy of GENERAL MOTORS COMPANY

    Piston Oil Nozzle (1) - Install [6x]

    2. CAUTION:

    Refer to Fastener Caution .

  2. Bolt@Piston Oil Nozzle (2) - Install and tighten [6x] - Fastener Specifications
  3. GM5148961Courtesy 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.
  4. Engine Block Core Hole Plug (1) - Install and tighten - Fastener Specifications
  5. Engine Front Cover Locating Pin (2) - Install [2x]
  6. Water Pump Plug (4) - Install
  7. Starter Locating Pin (3) - Install [2x]
  8. GM5148958Courtesy of GENERAL MOTORS COMPANY

    Cylinder Head Locating Pin (1, 2) - Install [2x]

  9. Transmission Locating Pin (3, 5) - Install [2x]
  10. 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.
  11. Engine Block Core Hole Plug (4) - Install and tighten - Fastener Specifications
  12. Seal@Engine Coolant Temperature Sensor (7) - Install NEW [2x]
    13. CAUTION:

    Refer to Component Fastener Tightening Caution .

  13. Engine Coolant Temperature Sensor (8) - Install and tighten [2x] - Fastener Specifications
  14. Seal@Engine Coolant Heater (6) - Install NEW
  15. Engine Coolant Heater (9) - Install and tighten - Fastener Specifications
    16. NOTE:

    When using the original crankshaft thrust bearing, ensure both are installed in the same position as removed.

  16. Lubricate the crankshaft thrust bearings with engine oil. Adhesives, Fluids, Lubricants, and Sealers
  17. Install the 2 crankshaft thrust bearings (2).
  18. GM5148482Courtesy of GENERAL MOTORS COMPANY

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

  19. Crankshaft (1) - Install
  20. GM5148487Courtesy of GENERAL MOTORS COMPANY

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

  21. 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

  22. Crankshaft Lower Bearing (1) @Crankshaft Bearing Cap (3) - Install [7x]
  23. 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]

  24. Crankshaft Bearing Cap Bolt (1) - Install NEW [14x]
  25. GM5148490Courtesy of GENERAL MOTORS COMPANY

    Tighten the 14 crankshaft bearing cap bolts in sequence. Fastener Specifications

  26. Coat the following components with engine oil:
    • Pistons
    • Connecting rods
    • Cylinder bores
    • Connecting rod bearings
  27. GM5148427Courtesy of GENERAL MOTORS COMPANY

    The arrow on the top of the pistons (1) must point to the front of the engine.

  28. GM5148428Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    If the old bearing will be reused, install in the original position.

    Connecting Rod Bearing (5, 6) - Install [2x]

    29. NOTE:

    When installing a piston into a cylinder, use a ring compressor sleeve or equivalent for best results. The following features should be looked for when selecting a ring compressor sleeve.

    • Hard anodized and Teflon coated for low friction and prolonged wear resistance.
    • Smooth radius that tapers down to the specific bore size.
    • Sleeve should compress the piston rings smoothly and evenly.
    • Using a ring compressor sleeve greatly reduces the difficulty with installing thin high-performance oil rings.

    If a ring compressor sleeve is unavailable, a universal ring compressor will work, but is more difficult to use.

  29. Compress the piston rings using a ring compressor sleeve or equivalent.
    30. NOTE:
    • If the old piston and connecting rod will be reused, install in the original position.
    • The mark (2) must point to the rear side of the engine.
  30. Using EN-51454  Connecting Rod Guides (4), install the 2 pistons (1, 3) with the connecting rods in cylinder 2 and cylinder 5.
  31. 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.

  32. Install 4 NEW connecting rod bearing cap bolts (3, 5) and tighten. Fastener Specifications
  33. Turn the crankshaft 120 degrees.
  34. GM5148432Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    If the old bearing will be reused, install in the original position.

    Connecting Rod Bearing (4, 6) - Install [2x]

  35. Compress the piston rings using a ring compressor sleeve or equivalent.
    36. NOTE:
    • If the old piston and connecting rod will be reused, install in the original position.
    • The mark (5) must point to the rear side of the engine.
  36. Using the EN-51454  Connecting Rod Guides (3), install the 2 pistons (1, 2) with the connecting rods in cylinder 1 and the cylinder 6.
  37. GM5148433Courtesy 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 1 and cylinder 6.

  38. Install 4 NEW connecting rod bearing cap bolts (3, 5) and tighten. Fastener Specifications
  39. Turn the crankshaft 120 degrees.
  40. GM5148434Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    If the old bearing will be reused, install in the original position.

    Connecting Rod Bearing (4, 5) - Install [2x]

  41. Compress the piston rings using a ring compressor sleeve or equivalent.
    42. NOTE:
    • If the old piston and connecting rod will be reused, install in the original position.
    • The mark (6) must point to the rear side of the engine.
  42. Using the EN-51454  Connecting Rod Guides (3), install the 2 pistons (1, 2) with the connecting rods in cylinder 3 and cylinder 4.
  43. 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.

  44. Install 4 NEW connecting rod bearing cap bolts (5) and tighten. Fastener Specifications
    45. NOTE:

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

  45. Clean all sealing surfaces.
  46. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  47. 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 (0.157 in) bead of sealer (1) along the perimeter of the sealing surface and at the center location, dimension a. Adhesives, Fluids, Lubricants, and Sealers

  48. 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
  49. GM5148171Courtesy of GENERAL MOTORS COMPANY

    Oil Pump Gasket (5) - Install NEW

  50. Upper Oil Pan Gasket (4) - Install NEW
    51. NOTE:

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

  51. Lower Crankcase Extension (2) - Install
  52. 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]

    53. NOTE:

    Take note that there are different bolt lengths.

  53. Lower Crankcase Extension Bolt - M6 (1, 2, 3) - Install and hand tighten [14x]
  54. GM5148172Courtesy of GENERAL MOTORS COMPANY

    Lower Crankcase Extension Bolt - M8 (4) - Tighten in sequence [7x] - Fastener Specifications

  55. Lower Crankcase Extension Bolt - M6 (1, 2, 3) - Tighten in sequence [14x] - Fastener Specifications
  56. GM5148147Courtesy of GENERAL MOTORS COMPANY

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

    57. NOTE:

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

  57. Oil Pump (1) - Install
  58. Check that the oil pump drive gear (3) sits correct in the oil pump drive shaft (4).
  59. GM5148146Courtesy of GENERAL MOTORS COMPANY

    Oil Pump Bolt (2, 3) - Install and hand tighten [4x]

  60. Connect the electrical connector. (1)
  61. GM5148148Courtesy of GENERAL MOTORS COMPANY

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

    62. NOTE:

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

  62. Clean all sealing surfaces.
  63. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  64. 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

  65. 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

  66. GM5145860Courtesy of GENERAL MOTORS COMPANY

    Oil Pan Bolt (1) - Install [23x]

  67. Oil Pan Bolt (1) - Tighten in sequence [23x] - Fastener Specifications
    68. 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.

  68. Clean all sealing surfaces.
    69. NOTE:

    For the piston overlap measurement, the piston has to stay on TDC.

  69. Measure the piston overlap:
    1. GM5149802Courtesy of GENERAL MOTORS COMPANY
      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.

    2. Zero the EN-571 - B  Dial Gauge (1) to the cylinder head deck surface.
    3. 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.
    4. Measure and note the piston overlap of the cylinder 1, first measurement.
    5. GM5149804Courtesy of GENERAL MOTORS COMPANY

      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.

    6. Measure and note the piston overlap of the cylinder 1, second measurement.
    7. Then repeat the procedure for the cylinder 6.
    8. GM5149806Courtesy of GENERAL MOTORS COMPANY

      Install the crankshaft pulley bolt to turn the crankshaft 120 degrees.

    9. Measure and note the piston overlap with the same 2 measure points at the cylinder 3 and cylinder 4.
    10. Turn the crankshaft 120 degrees.
    11. Measure and note the piston overlap with the same 2 measure points at the cylinder 2 and cylinder 5.
    12. 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).
  70. GM5149807Courtesy of GENERAL MOTORS COMPANY

    After the measurement of the piston overlap on all pistons, select the cylinder head gasket with the correct identification marks:

    1. 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).
    2. 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).
    3. 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).
  71. GM5214756Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • The EN-52586  Crankshaft Fixing Pin must be installed while the cylinder head is removed in order to achieve the proper alignment of the crankshaft and pistons for engine timing.
    • It may take multiple rotations of the crankshaft to get the correct alignment.

    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
    72. NOTE:

    Once the EN-52586  Crankshaft Fixing Pin is installed, do not remove until all timing components have been installed.

  72. EN-52586  Crankshaft Fixing Pin (4) - Install
  73. GM5149800Courtesy of GENERAL MOTORS COMPANY
    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.

    Install a NEW gasket. (2)

    74. NOTE:

    Ensure the 2 cylinder head locating pins (3) are properly seated in the engine block.

  74. Cylinder Head (1) - Install
  75. GM5149808Courtesy of GENERAL MOTORS COMPANY
    WARNING:

    Refer to Torque-to-Yield Fastener Caution .

    NOTE:

    Install NEW cylinder head bolts during assembly.

    Cylinder Head Bolt (1) - Install NEW [14x] - Fastener Specifications

  76. Cylinder Head Bolt (2) - Install [3x] - Fastener Specifications
  77. GM5318525Courtesy of GENERAL MOTORS COMPANY

    Prior to installation, mark the high pressure diesel fuel pump shaft (1) and fuel injection pump driven sprocket (2) in alignment to the keyway on the shaft.

  78. GM5145764Courtesy of GENERAL MOTORS COMPANY

    Lubricate the high pressure diesel fuel pump shaft (3) with engine oil. Adhesives, Fluids, Lubricants, and Sealers

  79. Fuel Pump Seal (2) - Install NEW
  80. High Pressure Diesel Fuel Pump (1) - Install
  81. GM5163876Courtesy 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.
  82. Fuel Injection Pump Bolt (1) - Install and tighten [3x] - Fastener Specifications
  83. GM5147858Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Guide (1) - Install

  84. GM5871991Courtesy of GENERAL MOTORS COMPANY

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

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

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

  87. GM5150342Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Guide (1) - Install

  88. 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.
    89. CAUTION:

    Refer to Fastener Caution .

  89. Timing Chain Guide Bolt (2) - Install and tighten [2x] - Fastener Specifications
  90. 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
    91. NOTE:

    The link at the crankshaft is difficult to see.

  91. If the 3 color links are not aligned, rotate the fuel injection pump shaft until alignment is achieved.
  92. 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.
  93. Install a NEW fuel injection pump bolt (1) and hand tighten.
  94. GM5147443Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Guide (1) - Install

  95. 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.
  96. Timing Chain Guide Bolt (2) - Install and tighten - Fastener Specifications
  97. GM5146080Courtesy of GENERAL MOTORS COMPANY

    Secondary Timing Chain (1) - Install

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

    Camshaft Sprocket (2) - Install

  100. Camshaft Position Sensor Exciter Wheel (1) - Install
  101. Camshaft Sprocket Bolt (3) - Install NEW and hand tighten
  102. 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.
  103. Timing Chain Guide Bolt (2) - Install and tighten [2x] - Fastener Specifications
  104. GM5145520Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Position Sensor Seal (1) - Install NEW

  105. Crankshaft Position Sensor (2) - Install
  106. Crankshaft Position Sensor Bolt (3) - Install and tighten - Fastener Specifications
  107. 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.

  108. GM5147524Courtesy of GENERAL MOTORS COMPANY

    Camshaft Sprocket Bolt (1) - Tighten - Fastener Specifications

  109. GM5237886Courtesy of GENERAL MOTORS COMPANY

    Timing Chain Tensioner (4) - Install

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

    Timing Chain Tensioner Gasket (1) - Install NEW

    112. CAUTION:

    Refer to Component Fastener Tightening Caution .

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

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

  115. GM5145487Courtesy of GENERAL MOTORS COMPANY

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

  116. Timing Belt (1) @Crankshaft - Install
  117. Oil Pump Sprocket (2) - Install
  118. GM5145486Courtesy of GENERAL MOTORS COMPANY

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

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

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

  122. Valve Rocker Arm (1) @Hydraulic Valve Lash Adjuster (2) - Install [24x]
  123. 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.

    Valve Rocker Arm (1) and Hydraulic Valve Lash Adjuster (2) - Install [24x]

  124. GM5147734Courtesy of GENERAL MOTORS COMPANY

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

  125. Check that the nose (1) of the EN-52445-1  Camshaft Tool sits correctly under the camshaft bearing rear cap (2).
  126. Check that the 2 pins (6) of the EN-52445-1  Camshaft Tool sit correctly in the 2 camshafts.
  127. GM5147733Courtesy of GENERAL MOTORS COMPANY

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

  128. Install the EN-52445-2  Camshaft Tool (1) to the camshafts.
  129. Washer (2) @ EN-52445-2  Camshaft Tool - Install
  130. Bolt (3) @ EN-52445-2  Camshaft Tool - Install and hand tighten
  131. 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]

  132. Camshaft Housing Gasket (2) - Install NEW
  133. GM5147736Courtesy of GENERAL MOTORS COMPANY

    Camshaft Housing (1) - Install

  134. Ensure that the camshaft housing is positioned correctly on the 2 camshaft housing cover locating pins (3, 4).
  135. Install and hand tighten the 6 bolts (2) of the EN-52445-1  Camshaft Tool.
  136. 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 camshaft housing is flush with the cylinder head.

  137. GM5147737Courtesy of GENERAL MOTORS COMPANY

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

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

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

  140. GM5146210Courtesy of GENERAL MOTORS COMPANY

    Bolt (1) @ EN-52445-2  Camshaft Tool - Remove

  141. EN-52445-2  Camshaft Tool (2) @CamshaftRemove
  142. GM5146041Courtesy of GENERAL MOTORS COMPANY

    Bolt (2) @ EN-52445-1  Camshaft Tool Holder - Remove [6x]

  143. EN-52445-1  Camshaft Tool Holder (1) - Remove
  144. GM5146047Courtesy of GENERAL MOTORS COMPANY

    O-Ring (3) @ EN-52445-2  Camshaft Tool - Remove

  145. Washer (2) @ EN-52445-2  Camshaft Tool - Remove
  146. GM5146210Courtesy of GENERAL MOTORS COMPANY

    EN-52445-2  Camshaft Tool (2) @CamshaftInstall

  147. Bolt (1) @ EN-52445-2  Camshaft Tool - Install
  148. GM5146206Courtesy of GENERAL MOTORS COMPANY

    Camshaft Sprocket (2) - Install

    149. NOTE:

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

  149. Camshaft Sprocket Bolt (1) - Install NEW
  150. Camshaft Sprocket Bolt (1) - Hand tighten
  151. GM5146078Courtesy of GENERAL MOTORS COMPANY

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

  152. 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).

  153. If the 2 colored links are not aligned, remove any components necessary and align the timing chain again.
  154. GM5146037Courtesy of GENERAL MOTORS COMPANY

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

  155. Bolt (1) @ EN-52445-2  Camshaft Tool Holder - Remove
  156. EN-52445-2  Camshaft Tool Holder (3) @CamshaftRemove
  157. GM5146042Courtesy of GENERAL MOTORS COMPANY

    EN-52586  Crankshaft Fixing Pin (1) - Remove

  158. Crankshaft Pulley Bolt - Remove [4x]
  159. GM5223852Courtesy of GENERAL MOTORS COMPANY
  160. Fuel Pump Access Hole Cover Seal (3) - Install NEW
  161. Fuel Pump Access Hole Cover (2) Install
  162. Timing Chain Cover Bolt (1) Install [2x] - Fastener Specifications
  163. GM5766443Courtesy of GENERAL MOTORS COMPANY

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

  164. Install the 4 EN-52446-4  Studs (3) in base.
  165. Place the timing chain lower cover (2) outward facing side up on the base.
  166. Install the EN-52446-2  Seal Protector (4) onto the EN-52446-3  Base (1).
  167. 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).
  168. Remove the EN-52446-2  Seal Protector (4).
  169. GM5766445Courtesy of GENERAL MOTORS COMPANY

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

  170. Install 4 washers (2) onto the EN-52446-4  Studs.
  171. Install the 4 EN-52446-5  Nuts (3) onto the studs.
  172. Tighten the 4 EN-52446-5  Nuts (3) evenly until the crankshaft rear oil seal (4) is fully seated in the cover.
  173. Remove the EN-52446  Assembly from the crankshaft rear oil seal (4).
  174. 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.

  175. Install the 4 EN-52446-4  Studs (2).
  176. Install the 4 EN-52446-5  Nuts (3) and hand tighten.
  177. 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.

  178. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  179. 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
  180. 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).

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

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

    185. NOTE:

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

  185. Clean all sealing surfaces.
  186. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  187. 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.
  188. GM5138708Courtesy of GENERAL MOTORS COMPANY

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

  189. Timing Chain Upper Cover (1) @Cylinder Head - Install
    190. NOTE:

    Take note that there are different bolt lengths.

  190. Apply sealant to the front threads of the 2 timing chain cover bolts (4).
  191. Timing Chain Cover Bolt (3, 4) - Install [6x] - Fastener Specifications
  192. Clean off the excess sealant residue between the timing chain upper cover and the cylinder head.
  193. Clean the glow plugs and mating hole. It must be free of lubricant and grease.
  194. 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 [6x] - Fastener Specifications

  195. GM5239643Courtesy of GENERAL MOTORS COMPANY

    Clean the camshaft housing gasket surface on the cylinder head.

  196. If the camshaft housing is reused, clean the camshaft housing seal groove.
  197. Camshaft Housing Gasket (1) @Camshaft Housing - Install NEW [2x]
  198. 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).

  199. 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, as shown. Adhesives, Fluids, Lubricants, and Sealers

  200. GM5239647Courtesy of GENERAL MOTORS COMPANY

    Camshaft Housing (1) @Cylinder Head - Install

  201. Camshaft Housing Bolt (2) - Hand tighten [26x]
  202. GM5138531Courtesy of GENERAL MOTORS COMPANY

    Camshaft Housing Bolt - Tighten in sequence - Fastener Specifications

  203. GM5136923Courtesy of GENERAL MOTORS COMPANY

    Clean the 6 fuel injector bores in the cylinder head.

  204. If the fuel injector is reused, clean the fuel injectors.
  205. Fuel Injector Seal (2) - Install NEW [6x]
  206. Fuel Injector Washer (3) - Install NEW [6x]
  207. High Pressure Diesel Fuel Injector (1) - Install [6x]
  208. GM5136920Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Pay attention to the mounting position of the injector brackets.

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

    209. NOTE:

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

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

    Charge Air Cooler Bracket (1) - Install

  211. High Pressure Diesel Fuel Injection Rail (2) - Install
    212. NOTE:

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

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

    Diesel Glow Plug Wiring Harness (3) - Install

  214. Electrical Connector (2) @Glow Plug - Connect [6x]
  215. Clip (1) @Diesel Glow Plug Wiring Harness - Install [3x]
  216. 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.
  217. 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.
  218. Fuel Injector Bolt (4) @Multiport Fuel Injector Bracket - Tighten [6x] - Fastener Specifications
  219. Tighten the 6 gray coded high pressure diesel fuel feed pipes nuts (3) at the fuel rail. Fastener Specifications
  220. Tighten the 6 black coded high pressure diesel fuel feed pipes nuts (5) at the fuel injector. Fastener Specifications
  221. GM5138462Courtesy of GENERAL MOTORS COMPANY

    Fuel Injection Fuel Feed Pipe Bracket (1) - Install

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

    Fuel Injector Fuel Return Hose Bracket (2) - Install

  224. Fuel Return Pipe Clip Bolt (1) - Install [2x] - Fastener Specifications
  225. 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).
  226. Fuel Feed Pipe Clip Bolt (2, 3) - Install [4x] - Fastener Specifications
  227. High Pressure Diesel Fuel Feed to Rail Pipe (1) - Tighten [4x] - Fastener Specifications
  228. GM5239993Courtesy of GENERAL MOTORS COMPANY

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

  229. GM5138347Courtesy of GENERAL MOTORS COMPANY

    Diesel Fuel Separator (2) - Install

  230. Front Fuel Return Pipe Connector (3) - Connect - Metal Collar Quick Connect Fitting Service
  231. Fuel Return Hose Connector Retainer (4) Engage
  232. Bolt (1) @Diesel Fuel SeparatorInstall - Fastener Specifications
  233. GM5138304Courtesy of GENERAL MOTORS COMPANY

    Fuel Pump Fuel Feed Hose (2) - Install

  234. Fuel Feed Hose Connector (4) - Connect - Metal Collar Quick Connect Fitting Service
  235. Fuel Feed Hose Connector Retainer (3) Engage
  236. Bolt (1) @Fuel Pump Fuel Feed Hose - Install - Fastener Specifications
  237. GM5138258Courtesy of GENERAL MOTORS COMPANY

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

  238. Fuel Injection Fuel Return Pipe (2) - Install
  239. Clip the fuel injection fuel pipe retainer (3) to the high pressure diesel fuel feed to rail pipe.
  240. 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.
  241. -Fuel Injection Fuel Return Pipe Clip (4) @High Pressure Diesel Fuel Injection Rail - Install
  242. 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.
  243. GM5214815Courtesy of GENERAL MOTORS COMPANY

    Fuel Injector Wiring Harness (3) - Install

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

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

  247. 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).
  248. EN-52586  Crankshaft Fixing Pin (4) - Install
  249. GM5133553Courtesy of GENERAL MOTORS COMPANY

    Clean the 8 crankshaft threads.

    250. NOTE:

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

  250. Position the flex plate (1) in order to align the flex plate alignment bore (2) to the crankshaft alignment bore.
  251. GM5133550Courtesy of GENERAL MOTORS COMPANY

    Automatic Transmission Flex Plate (1) - Install

  252. Automatic Transmission Flex Plate Bolt (2) - Install NEW [8x] - Fastener Specifications
  253. EN-52586  Crankshaft Fixing Pin - Remove
  254. Clean all sealing surfaces.
  255. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
  256. 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

  257. GM5148273Courtesy of GENERAL MOTORS COMPANY

    EN-52452  Front Crankshaft Seal Installer (1) @Crankshaft - Install

  258. Bolt (2) @ EN-52452  Front Crankshaft Seal Installer - Install and hand tighten
  259. GM5148276Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Front Oil Seal (1) - Install NEW

  260. Check that the crankshaft front oil seal sits correct on the crankshaft and on the engine front cover locating pins (2, 4)
  261. Bolt (5) @ EN-52452  Front Crankshaft Seal Installer - Remove
  262. EN-52452  Front Crankshaft Seal Installer (3) - Remove
  263. GM5148278Courtesy of GENERAL MOTORS COMPANY

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

  264. GM5137217Courtesy of GENERAL MOTORS COMPANY

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

  265. Water Pump Inlet Pipe (1) @Engine Block - Install
  266. Water Pump Gasket (3) @Water Pump (4) - Install NEW
  267. Water Pump (4) - Install
  268. Water Pump Bolt (5, 6) - Install [6x] - Fastener Specifications
  269. GM5137111Courtesy of GENERAL MOTORS COMPANY

    Crankshaft Pulley (1) - Install

  270. Crankshaft Pulley Bolt (2) - Install, but do NOT tighten [4x]
  271. -
    GM5137110Courtesy of GENERAL MOTORS COMPANY

    EN-49979  Holder (1) With EN-956-1  Extension (3) - Install

  272. Crankshaft Pulley Bolt (2) - Tighten - Fastener Specifications
  273. EN-49979  Holder With EN-956-1  Extension - Remove
  274. GM5136940Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Thermostat Housing Gasket (1) - Install NEW

  275. Engine Coolant Flow Control Valve (2) - Install
  276. Engine Coolant Flow Control Valve Bolt (3) Install [6x] - Fastener Specifications
  277. GM5136803Courtesy of GENERAL MOTORS COMPANY

    Engine Oil Cooler Gasket (3) - Install NEW

  278. Engine Oil Cooler Gasket (4) - Install NEW
  279. Engine Oil Cooler (2) - Install
  280. Engine Oil Cooler Bolt (1) - Install [5x] - Fastener Specifications
  281. GM5136785Courtesy of GENERAL MOTORS COMPANY

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

  282. Intake Manifold (1) - Install
  283. Intake Manifold Bolt (2) - Install [9x] - Fastener Specifications
  284. 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

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

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

  287. GM5136724Courtesy of GENERAL MOTORS COMPANY

    Clean the 12 cylinder head threads.

  288. Exhaust Manifold Gasket (1) - Install NEW
  289. Exhaust Manifold (2) - Install
  290. Exhaust Manifold Flange Bolt (3) - Install [12x] - Fastener Specifications
  291. GM5136722Courtesy of GENERAL MOTORS COMPANY

    Exhaust Manifold Heat Shield (1) Install

  292. Exhaust Manifold Heat Shield Bolt (2) - Install - Fastener Specifications
  293. GM5136702Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Oil Return Pipe Gasket (5) - Install NEW

  294. Turbocharger Oil Feed Pipe Gasket (6) - Install NEW
  295. Turbocharger Gasket (3) - Install NEW
  296. Turbocharger Assembly (1) - Install
  297. Turbocharger Nut (2, 4) - Install NEW [3x]
  298. Turbocharger Oil Return Pipe Bolt (8) - Install [2x] - Fastener Specifications
  299. Turbocharger Oil Feed Pipe Bolt (7) - Install [2x] - Fastener Specifications
  300. Turbocharger Oil Feed Pipe Bracket Bolt (9) Install - Fastener Specifications
  301. Turbocharger Nut (2, 4) - Tighten [3x] - Fastener Specifications
  302. GM5135382Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Valve Inlet Gasket (3) - Install NEW

  303. Exhaust Gas Recirculation Valve (2) - Install
  304. Exhaust Gas Recirculation Valve Bolt (1) - Install [2x] - Fastener Specifications
  305. GM5210041Courtesy of GENERAL MOTORS COMPANY

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

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

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

  308. Positive Crankcase Ventilation Hose (2) - Install
  309. GM5135087Courtesy 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.

    Camshaft Housing Cover Insulator (1) - Install

  310. GM5135048Courtesy of GENERAL MOTORS COMPANY

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

  311. Oil Level Indicator Tube (1) - Install
  312. GM5135046Courtesy of GENERAL MOTORS COMPANY

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

  313. Clip (4) @Oil Level Indicator Tube - Install
  314. Engine Oil Level Indicator (2) - Install
  315. GM5208673Courtesy of GENERAL MOTORS COMPANY

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

  316. Exhaust Gas Recirculation Cooler Inlet Pipe (2) - Install
    317. 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.

  317. Exhaust Gas Recirculation Cooler Bolt (1) - Install [2x] - Fastener Specifications
  318. GM5134623Courtesy of GENERAL MOTORS COMPANY

    Exhaust Gas Recirculation Pipe Seal (6) - Install NEW

  319. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (7) @Exhaust Gas Recirculation Cooler Outlet Pipe - Install NEW
  320. Exhaust Gas Recirculation Cooler Outlet Pipe (5) - Install
    321. NOTE:

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

  321. Exhaust Gas Recirculation Cooler Outlet Pipe Bolt (4) @Intake Manifold - Install [2x] - Fastener Specifications
    322. NOTE:

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

  322. Exhaust Gas Recirculation Cooler Bolt (1) @Exhaust Gas Recirculation Cooler Inlet Pipe - Install [2x] - Fastener Specifications
  323. Exhaust Gas Recirculation Outlet Pipe Bolt (3) @Fuel Injection Fuel Feed Pipe Bracket - Install - Fastener Specifications
  324. Exhaust Gas Recirculation Cooler Bolt (2) - Install - Fastener Specifications
  325. GM5138657Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Air Bleed Hose (1) - Install

  326. Engine Coolant Outlet Pipe Bracket Bolt (2) - Install - Fastener Specifications
  327. GM5138656Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Coolant Feed and Return Pipe Gasket (2, 4) - Install NEW

  328. Engine Coolant Air Bleed Hose Stud (1) - Loosely install
  329. Engine Coolant Air Bleed Pipe Bolt (3) - Install - Fastener Specifications
  330. Engine Coolant Air Bleed Hose Stud (1) - Tighten - Fastener Specifications
  331. GM5138658Courtesy of GENERAL MOTORS COMPANY

    Install the fuel injector wiring harness connector (1) to the engine coolant air bleed hose.

  332. Install the clip (2) to the engine coolant air bleed hose.
  333. GM5134476Courtesy of GENERAL MOTORS COMPANY

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

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

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

  337. Thermostat Bypass Hose (3) - Install
  338. Thermostat Bypass Pipe Bolt (2, 5) - Install [4x] - Fastener Specifications
  339. Thermostat Bypass Pipe Bolt (4) - Install - Fastener Specifications
  340. GM5134389Courtesy of GENERAL MOTORS COMPANY

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

  341. Thermostat Bypass Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type
  342. Thermostat Bypass Hose (2) - Install
  343. Thermostat Bypass Pipe Bolt (3) - Install [2x] - Fastener Specifications
  344. GM5485237Courtesy of GENERAL MOTORS COMPANY

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

  345. Thermostat Bypass Hose (1) - Install
  346. Water Outlet Stud (2) - Install - Fastener Specifications
  347. GM5217574Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Bracket (4) - Install

  348. Charge Air Cooler Bolt (3) - Install [5x] - Fastener Specifications
  349. GM5138644Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Bracket Brace (3) - Install

  350. Turbocharger Bracket Bolt (1) - Install - Fastener Specifications
  351. Turbocharger Bracket Nut (2) - Install [2x] - Fastener Specifications
  352. GM5133676Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler (4) - Install

  353. Charge Air Cooler Bolt (1) - Install [4x] - Fastener Specifications
  354. Intake Manifold Resonator (2) @Turbocharger - Install
  355. Retainer Spring@Intake Manifold Resonator (2) - Close
  356. Charge Air Cooler Outlet Air Hose (3) @Throttle Body Assembly - Install
    357. NOTE:

    Ensure the 3 hose clamp locating clips remain attached at the hose.

  357. Hose Clamp@Charge Air Cooler Outlet Air Hose (3) - Tighten - Fastener Specifications
  358. 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

  359. Clean and inspect the oil pan drain plug (1) and seal (2). Replace as necessary.
  360. Oil Pan Drain Plug Seal (2) - Install
  361. Oil Pan Drain Plug (1) - Install - Fastener Specifications
    362. CAUTION:

    If any malfunction is experienced which may cause debris to enter the oil supply, you must replace the engine oil cooler and hoses if equipped. Debris in the engine oil cooler and oil cooler hoses may be pulled back into the engine causing severe engine damage.

    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.

    NOTE:

    Engine prelubing is necessary by using a NEW engine block.

  362. GM5139662Courtesy of GENERAL MOTORS COMPANY

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

  363. Remove and discard the engine oil pressure sensor.
  364. Install the M12x1.75 adapter P/N 509376.
  365. 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.

  366. 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.
  367. Close the valve and remove the flexible hose and adapter from the engine.
  368. Engine Oil Pressure Sensor - Install NEW - Fastener Specifications
  369. Fill the engine oil to the proper level with NEW engine oil.
  370. Install the EN-52474  Engine Lift Hook Set.
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