Assembly

1. If removed, install oil gallery and cooling jacket plugs. To provide clearance for camshaft sprocket, oil gallery plugs on front of engine must be threaded below machined surface. Tighten plugs to specification.

NOTE:
- During engine assembly, a sealer will be applied to many components before installation. When the sealant is applied, the component should be installed within 15 minutes. After this time the sealant begins to set-up and its sealing effectiveness can be reduced.
- Lightly oil all retaining bolt and stud bolt threads before installation except those specifying special sealant with clean engine oil.
- Before installation, coat plug threads with Pipe Sealant with Teflon.

2. Install crankshaft as follows:
a. Install crankshaft main bearings in cylinder block. Note that third bearing from front is the crankshaft thrust main bearing.
b. Lubricate crankshaft main bearings with Engine Assembly Lubricant or clean, heavy engine oil and carefully lower crankshaft into place. Use care to prevent damage to crankshaft main bearing surfaces.
c. Apply a 3 mm (0.125 inch) bead of Silicone Rubber to cylinder block rear main bearing cap parting line.
d. Install crankshaft main bearings in main bearing caps and install caps. Note that caps are numbered with triangles. Number one is located at front of engine with triangle facing front of engine.
e. Install main bearing cap retaining bolts.
f. Before tightening main bearing cap bolts, wedge a large pry bar between cylinder block web and crankshaft cheek located in front of No. 3 crankshaft main bearing.

Do not jam pry bar into place. Tap into position only enough to hold crankshaft forward while main bearing cap bolts are tightened.

g. Tighten main bearing cap retaining bolts to 110-120 Nm (82-88 ft. lbs.) and remove pry bar.

3. Check crankshaft end play.





4. Install pistons as follows:
a. Install connecting rod bearings in connecting rods and connecting rod caps.
b. Install pistons and upper connecting rod bearings using Rotunda Piston Ring Compressor or equivalent. The stamped arrow in piston dome must face front of engine.

NOTE:
- Lubricate piston and cylinder walls with Engine Assembly Lubricant, or clean engine oil before installation.
- Scratching of crankshaft journal can be prevented by using connecting rod guide tool on connecting rod.

c. Install connecting rod caps, lower connecting rod bearings and retaining nuts. Tighten bolts to 40-45 Nm (30-33 ft. lbs.). Rotate nuts an additional 90-120 degrees.

5. Check connecting rod side clearance.
6. Coat sealing edge of camshaft rear bearing cover with Perfect-Seal Sealing Compound before installation.
7. Install camshaft rear bearing cover using a suitable driver.
8. Coat camshaft lobes and camshaft bearings with Engine Assembly Lubricant.
9. Install camshaft.





10. Install spacer and camshaft thrust plate.

NOTE: Camshaft spacer must be installed prior to key on camshaft. Both should be done prior to camshaft installation.

11. Install balance shaft, balance shaft thrust plate and gear as an assembly, and tighten retaining bolts to 8-14 Nm (71-124 inch lbs.).
12. Install engine balance shaft drive gear. Align balance shaft timing marks as shown.
13. Lubricate timing chain with clean engine oil.
14. Rotate crankshaft as necessary to position crankshaft keyway in 12 o'clock position. Install timing chain tensioner (retracted position).
15. Install camshaft sprocket, crankshaft sprocket and timing chain simultaneously. Pull pin on timing chain tensioner to release timing chain tensioner against chain.

NOTE: Do not remove pin at this time.





16. Make sure crankshaft keyway, camshaft sprocket timing mark and crankshaft sprocket timing mark are properly aligned after installation.
17. Install camshaft position sensor drive gear.
18. Install camshaft sprocket retainer bolt and washer and tighten to 40-50 Nm (29-37 ft. lbs.).
19. If water pump was removed from engine front cover during engine disassembly, position a new water pump housing gasket on engine front cover and install water pump.

Tighten water pump retaining bolts to 20-30 Nm (15-22 ft. lbs.).

20. Position a new engine front cover gasket on engine. Install engine front cover. Tighten attaching bolts to 20-30 Nm (15-22 ft. lbs.).
21. Install oil pump screen cover and tube using a new oil pump inlet tube gasket. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.), and support bracket retaining nut to 40-55 Nm (30-40 ft. lbs.).
22. Install oil pan as follows:
a. NOTE: Prior to applying sealer, clean oil pan and cylinder block sealing surfaces with Metal Surface Cleaner to remove all residues that may interfere with the sealer's ability to adhere.

Using a small-blade screwdriver, remove any sealer which may have been squeezed into seal groove when rear main bearing cap was installed. Place a 6.35 mm (0.25 inch) bead of Silicone Rubber into seal groove where bearing cap meets cylinder block.

b. Apply a 3 mm (0.125 inch) bead of Silicone Rubber to seams where engine front cover mates with cylinder blocks and to each end of oil pan end seal.
c. Apply a 3 mm (0.125 inch) bead of Silicone Rubber in zig-zag pattern to oil pan sealing surface.
d. Install oil pan. Tighten retaining bolts to 9-12 Nm (80-106 inch lbs.).

23. Install engine oil cooler (if equipped) and lubricate oil bypass filter gasket with clean engine oil and install oil bypass filter onto oil pump and filter body until gasket contacts oil pump and filter body, then tighten oil bypass filter an additional one-half turn.
24. Lubricate valve tappets with Engine Assembly Lubricant and install valve tappets. Install valve tappet guide plate and tappet guide plates and retainers.





25. Install new head gaskets using cylinder head to block dowels to align head gasket.
26. Position cylinder heads onto cylinder block.
27. Install cylinder head bolts (eight each side).

CAUTION: Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface area.

28. NOTE: When cylinder head retaining bolts have been tightened using the recommended procedure, it is not necessary to retighten bolts after extended engine operation. However, bolts can be checked for tightness if desired.

Tighten cylinder head retaining bolts in sequence as follows.
a. 20 Nm (15 ft. lbs.)
b. 40 Nm (29 ft. lbs.)
c. 50 Nm (37 ft. lbs.)





29. CAUTION: Do not loosen all of the bolts at the same time, only work on one bolt at a time.

In sequence, loosen retaining bolts two or three revolutions and retighten bolts in the following manner:
a. Long bolts:
- 40-50 Nm (30-36 ft. lbs.).
- Tighten an additional 175-185 degrees.
- Go to the next bolt in sequence.

b. Short bolts:
- 20-30 Nm (15-22 ft. lbs.).
- Tighten an additional 175-185 degrees.
- Go to next bolt in sequence.

30. Install push rods, rocker arms, rocker arm seats and retaining bolts.

NOTE: Lubricate push rod ends, rocker arm seats and rocker arms with Engine Assembly Lubricant or heavy engine oil before installation.

31. For each exhaust valve or intake valve, rotate crankshaft until valve tappet rests on heel (base circle) of camshaft lobe. Tighten rocker arm seat retaining bolt to 5 Nm (44 inch lbs.). Final tighten the rocker arm seat retaining bolts to 30-40 Nm (22-29 ft. lbs.). For final tightening, camshaft may be in any position.

NOTE: If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check.

32. Install lower intake manifold.
33. Install spark plugs.
34. Install valve covers as follows:
35. NOTE: Using solvent, clean valve cover and cylinder head sealing surfaces to remove all gasket material and dirt.

Install a new valve cover gasket onto valve cover.

36. Install valve cover and retaining bolts. Note location of stud bolts. Tighten to 8-11 Nm (71-97 inch lbs.).
37. Install camshaft position sensor housing and camshaft position sensor.
38. Install vibration damper using Damper/Front Cover Seal Replacer. Tighten retaining bolt to 140-180 Nm (104-132 ft. lbs.).
39. Install crankshaft pulley onto vibration damper. Tighten retaining bolts to 26-38 Nm (19-28 ft. lbs.).
40. Install fuel injectors and fuel injection supply manifold.
41. Install crankcase ventilation tube and positive crankcase ventilation valve.
42. Install upper intake manifold.
43. Connect ignition wires to spark plugs.
44. Install water bypass tube. Tighten retaining bolt to 8-11 Nm (71-97 inch lbs.).
45. Install exhaust manifolds.
46. Install engine rear plate and flywheel. Tighten retaining bolts to 73-87 Nm (54-64 ft. lbs.) in standard cross-tightening sequence.

NOTE: Apply a thin coat of Pipe Sealant with Teflon to flywheel retaining bolt threads before installation.