Piston, Connecting Rod, and Bearing Installation

Tools Required


• J 29789 Piston Ring Compressor

• J 39946 Crankshaft Socket - 4.0 L and 4.6 L

• J 36660-A Torque Angle Meter

Piston and Connecting Rod Assembly Procedure
Rotate the crankshaft using the J 39946 in order to align the crankshaft connecting rod journal being serviced to BDC.
Liberally lubricate the cylinder walls, piston rings and piston skirts with clean engine oil.
Important: Connecting rod bearings that have been used in a running engine, must be replaced with NEW connecting rod bearings for reassembly.


Select the correctly numbered piston/connecting rod assembly for the cylinder. An arrow showing proper piston orientation is located on the top of the piston.



Compress the piston rings using the J 29789 or equivalent.
Important: Extreme care must be exercised when installing the piston and connecting rod in order to be sure the rod does not scrape or nick the cylinder bore or the crankshaft surfaces.


Using both hands, slowly guide the piston and connecting rod assembly into the cylinder from the top and bottom of the cylinder. DO NOT allow the connecting rod to contact the cylinder wall.
When the piston ring compressor contacts the deck surface, gently tap the piston into the cylinder using the handle end of a dead-blow hammer. Guide the connecting rod onto the crankshaft bearing journal while taping the piston into the cylinder.
Connecting Rod Bearing Clearance Measurement Procedure
Important: Connecting rod bearings that have been used in a running engine, must be replaced with NEW connecting rod bearings for reassembly.


Before final assembly it is important to check the clearance of the new connecting rod bearings.
Place a length of fresh, room temperature plastic gaging material all the way across all the connecting rod bearing journal.



Install the connecting rod end cap on its original connecting rod making sure the bearing lock tangs are aligned on the same side of the rod.



When properly installed, the connecting rod bearing cap notches should be paired, as shown, on the crankpin.



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: Reuse the old connecting rod bolts ONLY for measuring the connecting rod bearing clearance.


Lubricate connecting rod bolts with engine oil and install in the connecting rod.

Tighten
Tighten the connecting rod bolts to 30 N·m (22 lb ft).

Loosen the connecting rod bolts until the torque reading is zero.
Re-tighten the connecting rod bolts.
First Pass

Tighten
Tighten the connecting rod bolts to 25 N·m (18 lb ft).

Final Pass

Tighten
Tighten the connecting rod bolts an additional 110 degrees using the J 36660-A .

Allow the assembly to sit for at least 2 minutes.



Remove the connecting rod cap bolts.
Remove the connecting rod cap.



Determine the connecting rod bearing clearance by comparing the width of the flattened plastic gaging material at its widest point with the graduation on the gauging material container.
Compare the measurements with the engine mechanical specifications. Refer to Engine Mechanical Specifications .
If the new bearings do not provide the proper crankshaft to bearing clearance, re-measure the crankshaft journals for the correct specified size and check to make sure you have the correct new bearings. If the crankshaft journals are incorrectly sized, replace the crankshaft. No crankshaft machining is permitted and undersized bearings are not available.
Clean the plastic gaging material from the connecting rod bearing and crankshaft connecting rod bearing journal using a soft lint-free cloth.
Connecting Rod Final Assembly Procedure
Back the connecting rod away from the crankshaft in order to allow for lubricant application.
Coat the crankshaft connecting rod bearing journal and installed connecting rod bearings with GM crankshaft prelube GM P/N United States 1052367, GM P/N Canada 992869, or equivalent.
Guide the connecting rod onto the crankshaft connecting rod bearing journal.



Install the connecting rod end cap on its original connecting rod making sure the bearing lock tangs are aligned on the same side of the rod.



When properly installed, the connecting rod bearing cap notches should be paired, as shown, on the crankpin.



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: DO NOT reuse the old connecting rod bolts.


Lubricate the NEW connecting rod bolts with engine oil and install in the connecting rod.

Tighten
Tighten the NEW connecting rod bolts to 30 N·m (22 lb ft).

Loosen the connecting rod bolts until the torque reading is zero.
Re-tighten the connecting rod bolts.
First Pass

Tighten
Tighten the connecting rod bolts to 25 N·m (18 lb ft).

Final Pass

Tighten
Tighten the connecting rod bolts an additional 110 degrees using the J 36660-A .





During and after installation, check to make sure each piston is positioned properly in the correct cylinder. The locating arrow on the top each piston (1) must be pointing toward the front of the engine.
Repeat these procedures for the piston/connecting rod assembly that is using the common crankshaft connecting rod journal.
Measure the connecting rod side clearance between the two connecting rods that share the common crankshaft connecting rod journal.
Compare the measurements with the engine mechanical specifications. Refer to Engine Mechanical Specifications .
If the connecting rods do not provide the proper crankshaft side clearance inspect for the following conditions:
- If the clearance is too tight, ensure the connecting rods are not binding and can slide parallel to the crankpin. Re-measure the connecting rod widths for the correct specified size. If the connecting rods are incorrectly sized, replace the connecting rods.

- If the clearance is too loose, re-measure the connecting rod widths for the correct specified size. If the connecting rods are incorrectly sized, replace the connecting rods.

Repeat these procedures for the remaining piston/connecting rod assemblies using the J 39946 in order to rotate the crankshaft.

I need a short break.
Dino and Bambam need some attention. Dino is the puppy.

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Lower Crankcase Installation

Tools Required


• EN 46109 Guide Pins

• J 39946 Crankshaft Socket - 4.0L and 4.6L

• J 45059 Angle Meter





Important: Ensure components being sealed with RTV are assembled within 20 minutes. Components assembled after the RTV has skinned-over, approximately 20 minutes, will not seal properly.


Completely fill and slightly overfill the engine block seal groove with a continuous bead of RTV sealant GM P/N 12378521 or equivalent.
Ensure the RTV sealant GM P/N 12378521 or equivalent bead is higher then the rail surface (1) by 3 mm (0.118 in).



Using a suitable tool spread the sealant in the area near the oil drain back passages (1) away from the oil drain back passages toward the outboard edge of the rail surface.



To prevent shifting of the lower crankcase install one of the EN 46109 into a bolt hole in each rail.



Install the cleaned lower crankcase onto the engine.



Using a rubber mallet gently tap the lower crankcase into position.
Remove both of the EN 46109 .



Loosely install the crankcase perimeter bolts on the right side.



Loosely install the crankcase perimeter bolts on the left side.



Using a small long blade screwdriver clean out any sealant in the oil drain back passages (1).



Important: Ensure components being sealed with RTV are assembled within 20 minutes. Components assembled after the RTV has skinned-over, approximately 20 minutes, will not seal properly.


Using a NEW oil distribution plate place a continuous 3 mm (0.118 in) wide bead of RTV sealant GM P/N 12378521 or equivalent on top of the outer seal (1) of the oil distribution plate place.



To prevent shifting of the oil distribution plate install one of the EN 46109 into a bolt hole in each side of the lower crankcase.



Install the NEW oil distribution plate.
Remove both of the EN 46109 .



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the oil distribution plate bolts.

Tighten
Tighten the oil distribution plate bolts to 10 N·m (89 lb in).





Using a small long blade screwdriver clean out any sealant in the oil drain back passages.



Install the crankshaft oil scraper plate.
Install the main bearing bolts. Ensure the stud-head bolt (1) used for the oil suction tube support bracket is placed in the proper position.



Tighten the main bearing bolts in the proper sequence.
First Pass

Tighten
Tighten the main bearing bolts (1-20) to 20 N·m (15 lb ft ) in the proper sequence.

Final Pass

Tighten
Tighten the main bearing bolts (1-20) an additional 65 degrees in the proper sequence using the J 45059 .





Tighten the crankcase perimeter bolts in sequence shown.

Tighten
Tighten the crankcase perimeter bolts to 30 N·m (22 lb ft).





Using a small long blade screwdriver verify that the threaded holes for the oil pan bolts and the oil drain back passages are clear of sealant.



Lubricate the silicone seal (3) in the oil manifold plate. With a twisting motion, install the end of the oil pump pick-up tube (1).
Install the oil pump pick-up bolt (4) and nut (2).

Tighten

• Tighten the oil pump pick-up tube nut to 24 N·m (18 lb ft).

• Tighten the oil pump pick-up tube bolt to 10 N·m (89 lb in).





Install the crankshaft position (CKP) sensors. Ensure the CKP sensor with the darker colored connector end (1) is installed in the lower crankcase and CKP sensor with the lighter colored connector end (2) is installed in the block.
Install the CKP sensor bolts.

Tighten
Tighten the CKP sensor bolts to 10 N·m (89 lb in).

Using the J 39946 rotate the crankshaft until the number one piston is at top dead center (TDC) and the crankshaft key way is approximately at the 7 o'clock position.



Place the transaxle brace (1) in position on the cylinder block.
Install the transaxle brace bolts.

Tighten
Tighten the transaxle brace bolts to 50 N·m (37 lb ft).

You do not need to use the alignment pins EN 46109. The block has built in pins. Make sure the REAR MAIN SEAL DRAIN BACK is clear of RTV. I have seen one rear main leak that had been replaced and I would guess that this was not done. I did not see the engine out of the car so I am not sure.

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Oil Pan Installation

Tools Required
EN 46109 Guide Pins





Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the oil level switch (1).

Tighten
Tighten the oil level switch to 20 N·m (15 lb ft).





Important: Ensure components being sealed with room temperature vulcanizing (RTV) sealant are assembled within 20 minutes. Components assembled after the RTV sealant has skinned-over, approximately 20 minutes, will not seal properly.


Completely fill and slightly overfill the oil pan seal groove with a continuous bead of RTV sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent.
Ensure the RTV sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent bead is higher than the oil pan sealing surface (1) by 3 mm (0.118 in).



To prevent shifting of the oil pan, install one EN 46109 into a bolt hole in each side of the lower crankcase.



Position the oil pan onto the lower crankcase.



Loosely install several of the oil pan bolts.
Remove the EN 46109 .
Finish loosely installing the remaining oil pan bolts.



Tighten the oil pan bolts in the sequence shown.

Tighten

Tighten the oil pan bolts a first pass to 8 N·m (71 lb in) in the sequence shown.
Tighten the oil pan bolts a final pass to 12 N·m (106 lb in) in the sequence shown.
Clean off any sealant that has protruded to the exterior of the engine.

I hope everyone can handle the starter install so I will skip it.

OK the bottom end is about done and this should have taken about 2hrs. I do not plastic gauge the engine. I do not use rebuilt parts or reground cranks. I have never repaired an engine with a lower end failure. This would mean that all my cranks and rods are good. Now lets move on to the heads

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Cylinder Head Installation

Tools Required
J 45059 Angle Meter





Ensure all the cylinder head locating pins are securely mounted in the cylinder block deck face.
Make sure any old thread sealant material is removed from the cylinder head bolts holes in the cylinder block.
Important: Failure to remove all the old thread sealant material from the cylinder block could cause false torque readings.


Install a new right cylinder head gasket using the deck face locating pins for retention.



Install a new left cylinder head gasket using the deck face locating pins for retention.



Align the cylinder head with the deck face locating pins.
Place the cylinder head in position on the deck face.



Important: DO NOT reuse the old M11 cylinder head bolts.


Install new M11 cylinder head bolts (1) in the cylinder head.
Install the M6 cylinder head bolts (2) at the front of the cylinder head.
Repeat these procedures for the remaining cylinder head.



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Tighten the left cylinder head bolts in the sequence shown.
First Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts to 30 N·m (22 lb ft ) in the sequence shown.

Second Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts an additional 60 degrees in the sequence shown using the J 45059 .

Third Pass

Tighten
Repeat the sequence turning each bolt another 60 degrees.

Final Pass

Tighten
Repeat the sequence again turning each bolt a final 60 degrees (total 180 degrees).

Tighten the M6 bolts at the front of the cylinder head.

Tighten
Tighten the M6 cylinder head bolts to 12 N·m (106 lb in).





Tighten the right cylinder head bolts in the sequence shown.
First Pass

Tighten
Tighten the right cylinder head M11 cylinder head bolts to 30 N·m (22 lb ft) in the sequence shown.

Second Pass

Tighten
Tighten the right cylinder head M11 cylinder head bolts an additional 60 degrees in the sequence shown using the J 45059 .

Third Pass

Tighten
Repeat the sequence turning each bolt an another 60 degrees.

Final Pass

Tighten
Repeat the sequence again turning each bolt a final 60 degrees (total 180 degrees).

Tighten the M6 bolts at the front of the right cylinder head.

Tighten
Tighten the M6 cylinder head bolts to 12 N·m (106 lb in).





Install the oil gallery plugs at the front and rear of the cylinder head.

Tighten
Tighten the oil gallery plugs to 12 N·m (106 lb in).

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

I will skip the crossover for now. It is on the list next, but the cams need to be in first.

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Camshaft Installation
Install the valve lifters with the flat surface facing up.



Clean the camshaft carriers with a clean, lint-free cloth.
Apply a liberal amount of clean engine oil to the carriers.
Place the camshaft in the camshaft carriers with the camshaft sprocket drive pins at the top of their rotation. The camshafts can be identified by a stamping near the rear journal. For example: L-EXH is defined as Left Bank Exhaust.



Install the camshaft bearing caps according to the identification marks. The arrow should point toward the front of the engine. The number indicates the position from the front of the engine and the I or E indicates intake or exhaust camshaft.
Hand start all the camshaft bearing cap bolts.



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Tighten the left cylinder head camshaft bearing caps.

Tighten
Tighten the camshaft bearing cap bolts in sequence shown to 5 N·m + 30 degrees (44 lb in + 30 degrees).





Tighten the right cylinder head camshaft bearing caps.

Tighten
Tighten the camshaft bearing cap bolts in sequence shown to 5 N·m + 30 degrees (44 lb in + 30 degrees).

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Camshaft Intermediate Drive Shaft Installation




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the intermediate sprocket shaft (1) and the retaining bolts.
Tighten
Tighten the intermediate sprocket shaft bolts to 10 N·m (89 lb in).

Camshaft Intermediate Drive Shaft Installation

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Primary Camshaft Drive Chain Installation
Tools Required
J 39946 Crankshaft Socket - 4.0L and 4.6L





Install the primary camshaft drive chain on the camshaft intermediate drive shaft sprocket and crankshaft sprocket.
Align the timing marks (1) of the camshaft intermediate drive shaft sprocket and crankshaft sprocket. Ensure the marks are aligned vertically.



Ensure the number one piston is at Top Dead Center (TDC) and the crankshaft pin (1) is approximately at the one o'clock position using the J 39946 .
Install the primary camshaft drive chain, camshaft intermediate drive shaft sprocket and crankshaft sprocket as an assembly (3) onto the camshaft intermediate drive shaft (4) and the crankshaft (2).



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the camshaft intermediate drive shaft sprocket bolt.
Tighten
Tighten the camshaft intermediate drive shaft sprocket bolt to 60 N·m (44 lb ft).





Install the primary camshaft drive chain guide (1).
Install the primary camshaft drive chain guide bolts.
Tighten
Tighten the primary camshaft drive chain guide bolts to 25 N·m (18 lb ft).





Collapse the primary camshaft drive chain tensioner using the following procedure:
8.1. Rotate the ratchet release lever counterclockwise and hold.

8.2. Collapse the primary camshaft drive chain tensioner shoe and hold.

8.3. Release the ratchet lever and slowly release the pressure on the shoe.

When the ratchet lever moves to the first detent a click should be heard and felt. Insert a pin through the hole in the release lever in order to lock the primary camshaft drive chain tensioner shoe in the collapsed position.



Important: Ensure the primary camshaft drive chain tensioner release lever is facing out.

Install the primary camshaft drive chain tensioner.
Install the primary camshaft drive chain tensioner bolts.
Tighten
Tighten the primary camshaft drive chain tensioner bolts to 25 N·m (18 lb ft).

Remove the pin in the release lever locking the primary camshaft drive chain tensioner.



Ensure the timing marks (1) are aligned vertically.

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Secondary Camshaft Drive Chain Installation
Install all eight spark plugs.
Lock the flywheel to prevent crankshaft rotation.



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the left timing chain tensioner shoe (1) and retaining bolt.

Tighten
Tighten the left timing chain tensioner shoe bolt to 25 N·m (18 lb ft).





Install the left timing chain guide (1) and lower retaining bolt.



Install the left timing chain by feeding the chain down through the cylinder head and hanging the chain on the camshafts.
Route the left timing chain over the inner row of the intermediate sprocket teeth.
Install the left guide upper retaining bolt through the cylinder head access hole.

Tighten
Tighten the left timing chain guide bolts to 25 N·m (18 lb ft).

Install the intake and exhaust camshaft sprockets into the chain and onto the camshafts so that the sprocket notch marked LI (left head intake) engages the intake cam drive pin and the sprocket notch marked LE (left head exhaust) engages the exhaust cam drive pin.
Loosely install the intake and exhaust camshaft sprocket retaining bolts.



Check the sprocket drive pin, it must be perpendicular to the head face.



Use the hex cast into the camshafts in front of the first set of lobes to reposition the camshafts if necessary.



Install the right timing chain guide and lower retaining bolt.



Install the right timing chain by feeding the chain down through the cylinder head and hanging the chain on the camshafts.
Route the right timing chain over the outer row of intermediate sprocket teeth.
Install the right chain guide upper retaining bolt through the cylinder head access hole.

Tighten
Tighten the right timing chain guide bolts to 25 N·m (18 lb ft).





Install the intake and exhaust camshaft sprockets into the chain and onto the camshafts so that the sprocket notch marked RI (right head intake) engages the intake cam drive pin and the sprocket notch marked RE (right head exhaust) engages the exhaust cam drive pin. The cam drive pin must be perpendicular to the head face. A hex is cast into the camshafts in front of the lobes for cylinder 1 so that an open end wrench may be used in order to provide minor repositioning of the cams.
Loosely install the intake and exhaust camshaft sprocket retaining bolts.



Install the timing chain guide access plugs (1) in the front of the cylinder heads.

Tighten
Tighten the chain guide access plugs to 4.5 N·m (39 lb in).





Collapse the secondary drive chain tensioners using the following procedure:
Rotate the ratchet release lever counterclockwise and hold.
Collapse the tensioner shoe and hold.
Release the ratchet lever. Slowly release the pressure on the shoe.
As the ratchet lever moves to its first click, hold the tensioner shoe inward and insert a pin through the hole in the release lever. The locked ratchet mechanism should hold the shoe in a collapsed position.



Important: Make sure the tensioner release lever faces toward you before tightening.



Install the left timing chain tensioner and retaining bolts.

Tighten
Tighten the secondary drive chain tensioner bolts to 25 N·m (18 lb ft).





Important: Make sure the tensioner release lever faces toward you before tightening.


Install the right timing chain tensioner and retaining bolts.

Tighten
Tighten the secondary drive chain tensioner bolts to 25 N·m (18 lb ft).





Tighten the camshaft sprocket bolts. Use the hex cast into each camshaft to prevent engine rotation and provide leverage.

Tighten
Tighten the camshaft sprocket bolts to 120 N·m (90 lb ft).





Install the camshaft position sensor (1) and retaining bolt.

Tighten
Tighten the camshaft position sensor retaining bolt to 10 N·m (89 lb in).





Check all timing marks to make sure they are in proper position for base engine timing.
When proper timing is assured, remove all pins from the timing chain tensioner release levers allowing the tensioner to expand and remove any slack in the timing chains.
Check for proper base engine timing.

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Oil Pump Installation

Tools Required
J 36660-A Torque Angle Meter





Install the oil pump drive spacer into the oil pump so that the drive flat engages the pump rotor.
Position the oil pump on the crankshaft.
Install the retaining bolts.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Apply upward pressure on the pump while tightening the three retaining bolts. Tighten the bolts in the sequence (1, 2, 3) shown.
First Pass

Tighten
Tighten the oil pump mounting bolts in sequence to 10 N·m (89 lb in).

Final Pass

Tighten
Tighten the oil pump mounting bolts in sequence an additional 35 degrees using the J 36660-A .

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

Engine Front Cover Installation
Tools Required
J 28410 Gasket Remover (Aluminum Components)





Using the J 28410 remove any cured excess RTV sealant at the split line of the upper and lower crankcase (1).
Place a small amount of fresh RTV sealant GM P/N 12378521, (Canadian P/N 88901148), or equivalent at the split line of the upper and lower crankcases (1).



Place the engine front cover gasket over the crankcase dowel pins.
Place the engine front cover in position on the crankcase.
Apply the thread locking compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the engine front cover bolts.
Install the engine front cover bolts.



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Tighten the engine front cover bolts in the sequence shown.
Tighten
Tighten the engine front cover bolts in the proper sequence to 10 N·m (89 lb in).

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

A cartridge type crankshaft rear main seal (Figure 1 - number 3) has been released for the 4.0L and 4.6L engines identified above. The cartridge type crankshaft rear main seal is identified by a metal flange located on the inner diameter of the seal which presses onto the crankshaft. The previous crankshaft rear main seal (Figure 1 - number 2) is a conventional lip type seal and has a soft rubber like material in the center where it contacts the crankshaft instead of this metal flange.

Important: The cartridge type crankshaft rear main seal is retained to the crankshaft with a press fit that requires over 45 kg (100 lb) of force to remove or install.

These high removal and installation forces make it necessary to remove the cartridge type crankshaft rear main seal with Kent-Moore Tool J 42841 (Figure 2) and install it with Kent-Moore Tool J 42842 (Figure 3). Refer to SI for Crankshaft Rear Oil Seal Replacement (Cartidge Type Seal) for instructions on the proper use of these tools. In addition, the cartridge type crankshaft rear main seal incorporates precise internal sealing surface relationships which are maintained for optimal sealing by using Kent-Moore installation tool J 42842.

DO NOT use Kent-Moore Tool J 38817-A (Figure 1 - number 1) to install the cartridge type crankshaft rear main seal. Attempting to install the cartridge type crankshaft rear main seal with Kent-Moore Tool J 38817-A will result in a damaged or improperly installed crankshaft rear main seal and will damage Kent-Moore Tool J 38817-A.

The cartridge type crankshaft rear main seal will be used to service 1996-1999 past model engines built after Engine Unit Number (EUN) T10L423109 which were installed in vehicles built after March, 1996.

Figure 1


(1) J 38817-A Rear Main Seal Installer
(2) P/N 12556355 Crankshaft Rear Main Seal supersede to P/N 12568025
(3) P/N 12568025 Crankshaft Rear Main Seal (Cartridge Type)
(4) J 42842 Crankshaft Rear Oil Seal Installer


------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

[This message has been edited by AJxtcman (edited 03-17-2007).]

THIS IS THE WAY TO PRIME THE OIL SYSTEM
I have worn this tool out and now use the oil from the gun. Remember 2 quarts min. I leave the filter on and remove the Oil Pressure Sensor and connect it to that port.
--------------------------------------------------------------------------------

Engine Prelubing
Tools Required
• J 42907 Oil Pressure Tester

• J 45299 Engine Preluber





Remove the engine oil filter.



Install the J 42907 onto the oil filter adapter.



Install the 1/8 NPT fitting from the J 45299 into the port on the J 42907 .



Install the J 45299 flexible hose to the fitting.



Open the valve of the J 45299 .
Important: A constant and continuous flow of clean engine oil is required in order to properly prime the engine. Use the approved engine oil as specified in the owner’s manual.

Pump the handle of the J 45299 in order to flow a minimum of 1-1.9 liters (1-2 quarts) of fresh clean engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
Close the valve of the J 45299 .



Remove the J 45299 flexible hose.



Remove the fitting from the J 42907 .



Remove the J 42907 from the oil filter adapter.
Ensure the NEW oil filter is filled with clean fresh engine oil.
Notice: Refer to Fastener Notice in Cautions and Notices.





Install the NEW oil filter.
Tighten
Tighten the oil filter to 32 N·m (24 lb ft).
------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

[This message has been edited by AJxtcman (edited 02-25-2007).]

Engine Flywheel Installation

Tools Required


• J 36660-A Torque Angle Meter

• J 44214 Flywheel Holder

Apply sealant, GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the engine flywheel retaining bolts.



Place the engine flywheel in position on the crankshaft.
Slip one bolt into the engine flywheel washer.
Install the washer and bolt in a location at the top of its rotation allowing the engine flywheel to hang in position.



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the remaining engine flywheel bolts.
Install the J 44214 to the engine block.
First Pass

Tighten
Tighten the engine flywheel retaining bolts to 15 N·m (11 lb ft).

Final Pass

Tighten
Tighten the engine flywheel retaining bolts an additional 50 degrees using the J 36660-A .

------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

I think everyone can handle the crossover and accessories bolt on's.
.
.
Please PM me if you need me to add.
.
.

Fastener Tightening Specifications
Application.....................................................Specification................Metric........ English

Air Conditioning Compressor Bracket to Lower Crankcase Lock Nut........30 N·m........22 lb ft
Air Conditioning Compressor Bracket to Lower Crankcase Stud..............25 N·m........18 lb ft
Air Conditioning Compressor to Block and Bracket...............................50 N·m........37 lb ft
Air Conditioning Compressor Mounting Bracket to Compressor...............25 N·m........18 lb ft

Brace--Left Bank (Long)...............................................................75 N·m.........55 lb ft
Brace--Left Bank (Short)..............................................................50 N·m.........37 lb ft
Braces--Right Bank.....................................................................50 N·m.........37 lb ft

Camshaft Bearing Cap....................................................................12 N·m.........106 lb in
Camshaft Chain Guide Access Plug...................................................4.5 N·m........39 lb in
Camshaft Cover.............................................................................10 N·m..........89 lb in
Camshaft Drive Chain Guide Bolts......................................................25 N·m.........18 lb ft
Camshaft Drive Chain Tensioner to Block............................................25 N·m.........18 lb ft
Camshaft Seal Retainer to Cam Cover (Left Hand Head)........................3 N·m.,........27 lb in
Camshaft Sprocket........................................................................120 N·m........89 lb ft

Catalytic Converter to Exhaust Manifold Rear Pipe............................... 50 N·m.........37 lb ft

Connecting Rod Bolt
First Pass ..................................................................................... 30 N·m.........22 lb ft
Second Pass ...................................................................................Back off to zero
Third Pass ...................................................................................... 25 N·m.........18 lb ft
Final Pass ...................................................................................... +110 degrees

Coolant Temperature Sensor..............................................................20 N·m......... 15 lb ft

Crankshaft Balancer Bolt
First Pass .......................................................................................50 N·m.........37 lb ft
Final Pass .....................................................................................+120 degrees

Crankshaft Position Sensor...............................................................10 N·m..........89 lb in

Cruise Control Bracket to Throttle Body Bracket.................................12 N·m..........106 lb in

Cylinder Block Coolant Heater - Right & Left.......................................10 N·m..........89 lb in

Cylinder Head Bolt (M11)
First Pass .......................................................................................30 N·m.........22 lb ft
Second Pass ...................................................................................+60 degrees
Third Pass .......................................................................................+60 degrees
Final Pass ...............................................................................+60 degrees (180 degrees Total)
Cylinder Head Bolt (M6).....................................................................12 N·m.........106 lb in
Cylinder Head Plug............................................................................80 N·m..........59 lb ft
Cylinder Head Plug (Oil Gallery).........................................................12 N·m.........106 lb in
Cylinder Head Plug (Soc Hex)............................................................5.5 N·m.........49 lb in

Drive Belt Idler Pulley.........................................................................50 N·m..........37 lb ft
Drive Belt Tensioner...........................................................................50 N·m..........37 lb ft

EGR Pipe (to Intake Manifold).............................................................25 N·m..........18 lb ft
EGR Tube (to Water Crossover)..........................................................25 N·m..........18 lb ft
EGR Tube to Intermediate Pipe Nut.....................................................60 N·m..........44 lb ft
EGR Valve........................................................................................25 N·m..........18 lb ft

Engine Flywheel Bolt
First Pass .......................................................................................15 N·m...........11 lb ft
Final Pass ....................................................................................... +50 degrees

Exhaust Manifold Pipe to Cylinder Head...............................................25 N·m..........18 lb ft
Exhaust Manifold Pipe to EGR Tube....................................................60 N·m..........44 lb ft
Exhaust Manifold Pipe to Exhaust Manifold Rear Pipe...........................25 N·m.........18 lb ft
Exhaust Manifold Pipe to Lower Crankcase..........................................25 N·m..........18 lb ft
Exhaust Manifold Rear Pipe to Right Manifold......................................40 N·m...........30 lb ft
Exhaust Manifold to Cylinder Head Lock Nut........................................25 N·m..........18 lb ft
Exhaust Manifold to Cylinder Head Bolt...............................................25 N·m...........18 lb ft

Flywheel Housing Cover Bolt...............................................................9 N·m............80 lb in

Front Cover Bolt................................................................................10 N·m............89 lb in

Generator and Air Conditioning Bracket to Block Bolt...........................50 N·m............37 lb ft
Generator Bracket to Block (Rear Bolt)...............................................47 N·m............35 lb ft
Generator Bracket to Block (Rear Nut)...............................................38 N·m.............28 lb ft
Generator to Bracket (Front Lower Bolt)............................................ 50 N·m.............37 lb ft
Generator to Bracket (Front Upper Bolt).............................................50 N·m.............37 lb ft
Generator to Bracket (Rear Bolt).......................................................50 N·m.............37 lb ft

Ignition Module Bolt (to Cam Cover)..................................................12 N·m.............106 lb in

Intake Manifold Bolt
10 N·m
89 lb in

Intermediate Sprocket Retaining Bolt
60 N·m
44 lb ft
Intermediate Sprocket Shaft Bolt
10 N·m
89 lb in

Knock Sensor
20 N·m
15 lb ft

Lift Bracket--Front
50 N·m
37 lb ft
Lift Bracket--Right Rear
50 N·m
37 lb ft

Lower Crankcase to Block (M8 x 1.25)
30 N·m
22 lb ft
Lower Crankcase Bolt/Stud (In Sequence) (M10 x 1.5)
First Pass
20 N·m
15 lb ft
Final Pass
+65 degrees

Oil Cooler lines to Oil Cooler
18 N·m
13 lb ft
Oil Cooler Lines to Oil Filter Adapter
18 N·m
13 lb ft
Oil Filter Adapter
16 N·m
12 lb ft
Oil Filter Adapter Plug w/Oil Cooler
20 N·m
15 lb ft
Oil Filter Adapter Plug w/o Oil Cooler
18 N·m
13 lb ft

Oil Level Indicator Tube
10 N·m
89 lb in

Oil Level Sensor
20 N·m
15 lb ft

Oil Manifold Plate to Lower Crankcase
10 N·m
89 lb in

Oil Pan Bolt
First Pass
8 N·m
71 lb in
Final Pass
12 N·m
106 lb in

Oil Pan Brace
50 N·m
37 lb ft

Oil Pan Drain Plug
20 N·m
15 lb ft

Oil Pump Suction Pipe (Lock Nut)
25 N·m
18 lb ft

Oil Pump to Lower Crankcase
First Pass
10 N·m
89 lb in
Final Pass
+35 degrees

Oxygen Sensor
40 N·m
30 lb ft

Power Steering Pump (to Bracket)
25 N·m
18 lb ft
Power Steering Pump Bracket (to Block)
50 N·m
37 lb ft

Starter (to Block)
30 N·m
22 lb ft
Starter Motor (Lock Nut)
10 N·m
89 lb in

Thermostat Outlet to Water Pump Cover
10 N·m
89 lb in

Torque Converter to Flywheel Bolt
47 N·m
35 lb ft

Torque Strut Bracket to Cylinder Head
50 N·m
37 lb ft
Torque Strut Bracket to Cylinder Head (Stud)
50 N·m
37 lb ft
Torque Strut Bracket to Water Manifold
25 N·m
18 lb ft

Transaxle Bel Housing to Engine
75 N·m
55 lb ft

Water Crossover (to Block)
25 N·m
18 lb ft
Water Crossover (to Head)
25 N·m
18 lb ft
Water Crossover Plug
25 N·m
18 lb ft

Water Outlet Fitting
50 N·m
37 lb ft

Water Outlet to Cylinder Head
25 N·m
18 lb ft

Water Pump Assembly
100 N·m
74 lb ft

Water Pump Drive Belt Shield Retaining Bolt
10 N·m
89 lb in
Water Pump Drive Belt Shield Retaining Nut
10 N·m
89 lb in
Water Pump Drive Belt Tensioner to Water Crossover (Stud)
10 N·m
89 lb in
Water Pump Cover to Water Pump Housing
10 N·m
89 lb in



------------------
Cadillac Tech
ASE MASTER TECH since 1988

86 Northstar Fiero
85 RX7 former SCCA car
56 TR3 small mouth 6.0L
A.J. Whiteley

[This message has been edited by AJxtcman (edited 03-17-2007).]