Part 1
EngineSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Special Tool(s) (Part 3):
Material:
Assembly (Steps 1-39)
All vehicles
NOTE: This procedure assumes that the engine will be installed using the recommended body off engine installation procedure. If it will be necessary to install the engine using the alternate body on engine installation procedure, some of the components in this procedure should not be installed at this time.
1. NOTE: Check alignment of the oil holes after installing the bearings.
If removed, use the special tool to install the camshaft bearings.
2. CAUTION: The patch bolt is unique. Do not substitute the patch bolt or engine damage may occur.
NOTE: Apply Threadlock(R) to the threads prior to installation.
Install the 8 piston cooling tubes and the 8 bolts.
^ Tighten to 13 Nm (115 lb-inch).
3. CAUTION: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage may occur.
NOTE: Apply clean engine oil to the camshaft prior to installing.
Install the camshaft and gear assembly and the thrust plate mounting bolts.
^ Tighten to 31 Nm (23 lb-ft).
4. Install the crankshaft upper bearings and the crankshaft upper thrust bearing.
^ Apply clean engine oil to the crankshaft side of the bearings.
5. Using the special tool, align the camshaft timing mark as shown.
6. NOTE: Apply clean engine oil to the crankshaft bearing journals prior to installing the crankshaft.
With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.
7. NOTE: Do not turn the crankshaft during the main bearing clearance check.
Position commercially available Plastigage(R) in the center of each main bearing cap.
8. NOTE: The locking tabs on the bearings shell are directional.
Install the crankcase lower bearings into the lower crankcase.
9. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
NOTE: Lightly lubricate the new crankcase main bearing mounting bolt threads and flanges with clean engine oil.
Position the lower crankcase and install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in 3 stages in the sequence shown.
^ Stage 1: Tighten to 149 Nm (110 lb-ft).
^ Stage 2: Tighten to 176 Nm (130 lb-ft).
^ Stage 3: Tighten to 231 Nm (170 lb-ft).
10. Remove the 20 bolts and the lower crankcase,
11. Measure the clearances for the main bearings. Remove the Plastigage(R).
12. Install new lower crankcase seals. Apply clean engine oil to each crankshaft bearing.
13. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
Position the lower crankcase and install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in 3 stages in the sequence shown.
^ Stage 1: Tighten to 149 Nm (110 lb-ft).
^ Stage 2: Tighten to 176 Nm (130 lb-ft).
^ Stage 3: Tighten to 231 Nm (170 lb-ft).
14. NOTE: Failure to remove the special tool will result in incorrect readings.
Remove the bolt and special tool.
15. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
Using the special tool, measure the crankshaft end play.
16. Using the special tool, measure the camshaft end play.
17. Using the special tool, measure the camshaft gear backlash.
18. Install the block heater.
^ Tighten to 41 Nm (30 lb-ft).
19. Install the camshaft position (CMP) sensor and the bolt.
^ Tighten to 13 Nm (115 lb-inch).
20. Install the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 13 Nm (115 lb-inch).
21. CAUTION: The connecting rods are powdered metal cracked rods. Make sure the connecting rod and cap are installed as a set or engine damage may occur.
NOTE: Lubricate the connecting rod bearings with clean engine oil prior to installation.
Install the connecting rod bearings.
22. CAUTION: Make sure the ring openings are 120 degrees from each other or engine damage may occur.
Install new piston rings.
1 The top compression ring is identified with one indentation mark and a 15-degree keystone cross section. The ring must be installed with the indentation mark facing towards the piston crown (top).
2 The intermediate ring is identified with 2 indentation marks and a rectangular profile. The ring must be installed with the indentation marks facing towards the piston crown (top).
3 Install the oil control ring. Make sure the oil ring gap is 180-degrees from the spring wire latch.
23. NOTE: The piston assembly must be installed with the words "Cam Side" toward the inside of the engine, along with the long side of the connecting rod big end split.
NOTE: Use care when installing the piston assembly to not damage the piston cooling tubes. If the tube is bent during installation of the piston assembly, install a new piston cooling tube.
NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
Install the piston and rod assemblies.
1 Coat the inside diameter of the ring compressor with clean engine oil.
2 Insert the piston into the special tool. Position the piston, connecting rod and special tool into the correct cylinder bore.
^ Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.
24. Position a piece of Plastigage(R) across the bearing surface.
25. CAUTION: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.
Position the connecting rod cap and tighten the bolts in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 lb-ft).
^ Stage 2: Tighten to 68 Nm (50 lb-ft).
26. Remove the bolts and the connecting rod cap.
27. Measure the clearances for the connecting rod cap. Remove the Plastigage(R).
28. CAUTION: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.
Position the connecting rod cap and tighten the bolts in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 lb-ft).
^ Stage 2: Tighten to 68 Nm (50 lb-ft).
29. Using a feeler gauge, check for connecting rod side clearance.
30. NOTE: Upper oil pan gasket shown.
Install a new press-in-place upper and lower oil pan gasket into the upper oil pan.
31. Position the upper oil pan and install the bolts.
^ Tighten to 13 Nm (115 lb-inch).
32. Install a new O-ring seal. Install the oil pump screen and pickup tube and the bolts.
^ Tighten to 13 Nm (115 lb-inch).
33. Install the oil pan and the 20 bolts.
1 Install the 5 longer oil pan bolts.
2 Install the remaining oil pan bolts.
^ Tighten to 13 Nm (115 lb-inch).
34. CAUTION: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions.
Apply clean engine oil to the valve tappets and install them into the valve tappet guides. Install the valve tappet guides and the bolts.
^ Tighten to 13 Nm (115 lb-inch).
35. Install the 4 cylinder head dowels.
36. NOTE: Install a new cylinder head gasket with the part number facing up. Verify the top 5 bolt holes and the head gasket push rod holes line up.
NOTE: Use care to avoid scratching the blue compound on the cylinder head gaskets.
Place the new cylinder head gasket over the dowel sleeves and onto the crankcase.
37. Using the special tool, install the cylinder heads.
38. Install the 5 outer bolts for each cylinder head.
^ Tighten finger tight.
39. CAUTION: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.
NOTE: Left cylinder head shown, right cylinder head similar.
NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
Install the 10 cylinder head retaining bolts for each cylinder head.
^ Tighten finger tight.
