Buick Regal: Piston, Connecting Rod, and Bearing Installation

NOTE: This procedure is not used in Europe.

Special Tools

• EN-43953 Ring Compressor - 86 mm
• EN-43966 Connecting Rod Guides
• EN 45059 Angle Meter

For equivalent regional tools, refer to Special Tools.

1.

Ensure the piston ring end gaps are positioned 90 degrees to each other.

• Upper compression ring joint (1)
• Lower compression ring joint (2)
• Upper oil ring rail joint (5)
• Oil ring rail spacer joint (4)
• Lower oil ring rail joint (3)

2.

NOTE: The connecting rods and caps must be installed in the same order and orientation in which they were removed. If new connecting rods are required, the connecting rod is provided as an assembly, and the upper rod will need to be disassembled from the lower cap.

Install the connecting rod bearings. Use NEW bearings.

NOTE: The connecting rod bearing anti-rotation tab grooves are to point toward the right-hand side of the engine.

1. Install the bearing inserts into the connecting rod and the connecting rod cap.
2. Lubricate the connecting rod bearings with engine oil.

3. Install the EN-43966 guides (2) into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation.

4. Install EN-43953 compressor, piston (1), and the connecting rod to the correct bore.

1. Lubricate the piston and the piston rings with engine oil.
2. Do not disturb the piston ring end gap location.
3. The piston must be installed so that the arrow mark on the top of the piston points to the front of the engine.
4. Lubricate the engine bore with engine oil, then place the piston in its matching bore.
5. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place.
6. Hold the EN-43953 compressor against the engine block until all the rings have entered the cylinder bore.
7. Remove the connecting rod guides from the connecting rod bolt holes.

5.

NOTE: Ensure that the connecting rod cap is properly oriented on the connecting rod.

Install the connecting rod cap (1).

CAUTION: Refer to Fastener Caution. CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.

Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

6. Install the NEW connecting rod bolts (2).

1. Tighten all the connecting rod bolts a first pass to 25 N.m (18 lb ft).
2. Tighten all the connecting rod bolts a final pass an additional 110 degrees using the EN 45059 meter.

7. Install the remaining connecting rods and piston assemblies.

8.

NOTE: Rotate the crankshaft to ensure that it moves freely and does not bind.

Measure the connecting rod side clearance with a feeler gauge (1). Refer to Engine Mechanical Specifications.

9. Measure the piston deck height. Refer to Engine Mechanical Specifications.

BALANCER SHAFT WITH OIL PUMP INSTALLATION

1.

Install the balancer and oil pump shaft assembly (2).

2. Install the balancer and oil pump shaft assembly bolts (1) finger tight.

Fig. 13: Engine Balancer And Oil Pump Shaft Assembly Bolts Tightening Sequence

3.

Tighten the bolts twice in sequence:

1. Tighten the bolts a first pass in sequence to 58 N.m (43 lb ft).
2. Tighten the bolts a final pass in sequence to 58 N.m (43 lb ft).

CYLINDER HEAD INSTALLATION

Special Tools

EN 45059 Angle Meter

For equivalent regional tools, refer to Special Tools

1.

NOTE: Do not use any sealing material. Ensure that all mating surfaces are clean and free of debris.

If necessary, install NEW cylinder head locating pins.

2. Install the cylinder head gasket (3) to the block.

3. Install the cylinder head (2). Ensure the number 1 cylinder is at top dead center (TDC). The key on the crankshaft should be on top in the 12 o'clock position.

4.

CAUTION: Refer to Fastener Caution. CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.

Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

Install the NEW cylinder head bolts.

1. Tighten the bolts in sequence to 30 N.m (22 lb ft).
2. Tighten the bolts an additional 190 degrees in sequence using the EN 45059 meter.

WATER PUMP INSTALLATION

Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to ensure proper sealing.

1.

Install a NEW water pump gasket (6) and the water pump assembly (5).

2. Install the water pump bolts (1). Finger tighten the bolts.

CAUTION: Refer to Fastener Caution.

NOTE: The sequence allows the fasteners closest to compress the seal.

3. Tighten the water pump bolts in sequence to 25 N.m (18 lb ft).

4. Install a NEW thermostat assembly gasket (4) and the thermostat assembly (2).

5. Install the thermostat assembly bolts (3) and tighten to 10 N.m (89 lb in).

6.

Install a NEW water outlet assembly gasket (3), and the water outlet assembly (1).

7. Install the water outlet assembly bolts (4) and tighten to 10 N.m (89 lb in).

8. Install the engine coolant temperature sensor (2).

9. Install the engine coolant temperature sensor retaining clip (5).

10.

Connect the thermal bypass pipe (2) to the water outlet assembly.

11. Connect the thermal bypass hose to the engine oil cooler.

12. Install a NEW thermal bypass pipe gasket (3) on the thermal bypass pipe. Install the thermal bypass pipe to the water pump assembly. Install the bolts (1) and tighten to 10 N.m (89 lb in).

INTAKE AND EXHAUST CAMSHAFT, BEARING CAP, AND LASH ADJUSTER INSTALLATION

Exhaust Camshaft Installation

1.

Install the camshaft bearing lower front cap (1).

2.

NOTE: Pre-fill the low pressure chamber with engine oil. Maintain a vertical orientation of the assembly to retain the oil in the reservoir and high pressure chamber. Do not install the lash adjusters without pre-filling the low pressure chamber. Apply engine oil to the outer diameter surface of all adjusters.

Lubricate and install the hydraulic valve lash adjusters (1) into their bores in the cylinder head. Refer to Adhesives, Fluids, Lubricants, and Sealers.

3.

Lubricate the valve tips. Refer to Adhesives, Fluids, Lubricants, and Sealers.

4.

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

NOTE: Pre-oil roller bearings before installation.

Lubricate the roller bearings with valve rocker arm lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

5. Position the valve rocker arm (1) on the tip of the valve stem and on the lash adjuster and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers.

6.

NOTE: Apply lubricant to all lobes and journals prior to installing the camshafts.

Lubricate the exhaust camshaft lobes and journals with camshaft lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

7. Set the exhaust camshaft (1) on top of the rocker arms in the camshaft bearing journals with the actuator timing mark at approximately the 1 O'clock position.

NOTE:

• Do not apply final torque at this time. Camshaft cap final torque is applied in sequence when all caps are installed on both intake and exhaust camshafts.
• To properly position the camshaft caps, install the camshaft cap bolts into the camshaft caps prior to installing the camshaft caps on the camshafts.

8. Install the camshaft cap bolts (3) into the camshaft caps (2).

9. Install the camshaft caps (2) and hand start the camshaft cap bolts (3).

Intake Camshaft Installation

1.

NOTE: Pre-fill the low pressure chamber with engine oil. Maintain a vertical orientation of the assembly to retain the oil in the reservoir and high pressure chamber. Do not install the lash adjusters without pre-filling the low pressure chamber. Apply engine oil to the outer diameter surface of all adjusters.

Lubricate and install the hydraulic valve lash adjusters (1) into their bores in the cylinder head. Refer to Adhesives, Fluids, Lubricants, and Sealers.

2.

Lubricate the valve tips. Refer to Adhesives, Fluids, Lubricants, and Sealers.

3.

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

NOTE: Pre-oil roller bearings before installation.

Lubricate the roller bearings with valve rocker arm lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

4. Position the valve rocker arm (1) on the tip of the valve stem and on the lash adjuster and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers.

5.

NOTE: Apply lubricant to all lobes and journals prior to installing the camshafts.

Lubricate the intake camshaft lobes and journals with camshaft lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

Set the intake camshaft (3) on top of the roller followers in the camshaft bearing journals with the intake actuator timing mark at approximately the 11 O'clock position.

NOTE: To properly position the camshaft caps, install the camshaft cap bolts into the camshaft caps prior to installing the camshaft caps on the camshafts.

6. Install the camshaft cap bolts (1) into the camshaft caps (2, 4).

7. Install the camshaft caps (2) and hand start the camshaft cap bolts (1).

8. Install the camshaft rear cap (4) and hand start the camshaft cap bolts (1).

9.

CAUTION: Refer to Fastener Caution.

NOTE: During the tightening sequence, locate and tighten each camshaft cap bolt installed into the circular hole first. Then, tighten the bolt installed into the slotted hole.

Tighten the camshaft cap bolts in sequence using the following procedure:

1. Tighten the camshaft cap bolts in sequence to 8 N.m (71 lb in).
2. Loosen both bolts in each cap in sequence to 180 degrees.
3. Tighten the camshaft cap bolts in sequence to 10 N.m (89 lb in) twice.

10.

Install the front camshaft bearing cap (1). Install the 2 outer bolts (2) for the front camshaft bearing cap finger tight. Installation of the timing chain guide and bolts, and final torque for the front bearing cap is not performed until after the timing chain is installed.

BALANCER CHAIN, SPROCKET, AND TENSIONER INSTALLATION

Special Tools

EN-50837 Timing Chain Tensioner Retraction Tool

For equivalent regional tools, refer to Special Tools.

1.

NOTE: Proper setup is critical to ensure correct timing when installing the sprockets and chain simultaneously onto the shafts. The timing links are heat treated blued steel.

Assemble the crankshaft sprocket, balancer shaft driven sprocket, and balancer chain. Ensure the timing link (1) lines up with the timing mark (2) on the crankshaft sprocket. Ensure that both timing teeth (3) on the balancer shaft driven sprocket line up with the timing links (4).

2.

NOTE: The crankshaft keyway should be in the 12 O'clock position.

Install the sprockets and chain (2) as an assembly to the crankshaft and balancer shaft assembly.

3. Install the crankshaft key (1).

4.

Ensure the timing link (1) is aligned with the crankshaft sprocket timing mark (2).

5. Ensure the adjacent timing links (4) are aligned with both of the timing marks (3) on the balancer shaft driven sprocket.

6.

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.

Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

Install the NEW balancer shaft driven sprocket bolt (1).

CAUTION: Refer to Fastener Caution.

7. Use an open end wrench over flat on balance shaft while tightening the balancer shaft sprocket bolt to specification. Tighten the balancer shaft driven sprocket bolt to 40 N.m (30 lb ft) plus 50 degrees.

8.

NOTE: Ensure the guide is installed in the correct orientation. The long end must point toward the crankshaft and the flat edge must be adjacent to the balance chain.

Install the balancer chain guide (2).

9. Install the balancer chain guide bolts (1). Tighten the bolts to 10 N.m (89 lb in).

10.

Install the balancer chain tensioner (2).

11. Install the balancer chain tensioner bolts (1). Tighten the bolts to 10 N.m (89 lb in).

12. Remove EN-50837 retention tool to restore the tension to the balancer chain.

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