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Special Tool(s)
CAUTION: If the supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
NOTE: Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.
1. Illustration 1 of 14. Install the components in the order indicated.
2. Illustration 2 of 14. On 4x4 vehicles only, install the components in the order indicated.
3. Illustration 3 of 14. Install the components in the order indicated.
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4. Illustration 4 of 14. Install the components in the order indicated.
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5. Illustration 5 of 14. Install the components in the order indicated.
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6. Illustration 6 of 14. Install the components in the order indicated.
7. Illustration 7 of 14. Install the components in the order indicated.
8. Illustration 8 of 14. Install the components in the order indicated.
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9. Illustration 9 of 14. Install the components in the order indicated.
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10. Illustration 10 of 14. Install the components in the order indicated.
11. Illustration it of 14. Install the components in the order indicated.
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12. Illustration 12 of 14. Install the components in the order indicated.
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13. Illustration 13 of 14. Install the components in the order indicated.
14. Install the engine lifting eyes and remove the engine from the engine stand.
15. Illustration 14 of 14. Install the components in the order indicated.
Item 2: Crankshaft Assembly Note
1. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance.
Install the crankshaft.
Item 3: Crankshaft Main Bearing Cap Assembly Note
1. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
Apply silicone gasket and sealant to the rear main bearing cap-to-cylinder block parting line.
Item 4: Crankshaft Main Bearing Cap Bolts Assembly Note
1. Tighten the bolts in the sequence shown to 97 Nm (72 ft. lbs.).
Items 6-10: Piston Assembly Assembly Note
1. Check the piston-to-cylinder bore and ring clearances.
2. NOTE: Lubricate the piston rings with clean engine oil.
Using a suitable tool, install the piston rings.
3. Make sure the piston ring gaps (oil spacer-A, oil ring-B, and compression ring-C) are correctly spaced around the circumference of the piston.
4. Install the connecting rod bearings.
5. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
6. NOTE: Position the piston with the indentation or arrow toward the front of the cylinder block.
Using the special tool, install the pistons.
^ Rotate the crankshaft as necessary.
7. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.
Check the clearance of each connecting rod bearing.
8. Rotate the crankshaft until the piston is at the bottom of its stroke.
9. NOTE: For cylinders 1, 2, and 3 remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5, and 6 remove the opposite nut first.
Loosen the first nut until the face is approximately 2 mm (0.08 inch) over the end of the bolt.
10. Tap the nut until the bolt can be removed by hand.
11. Repeat the previous two steps for the opposite bolt.
12. Install the new bolts, making certain that the new bolt head is parallel to the sideward face of the connecting rod.
13. NOTE: Install the connecting rod caps in their original position.
Install and tighten the connecting rod nuts in the sequence shown in two stages:
1 Stage 1: Tighten to 20 Nm (15 ft. lbs.).
2 Stage 2: Tighten 90 degrees.
14. Repeat these steps for the remaining connecting rods.
Item 12: Jackshaft Thrust Plate Assembly Note
1. Install the jackshaft thrust plate and bolts.
Items 15-21: Balance Shaft Drive Chain Assembly Note
1. Rotate the crankshaft until No. 1 piston is at Top Dead Center (TDC).
2. NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to seven complete turns of the balance shaft may be required to find the correct position.
Align the timing marks.
^ Install a 4 mm (0.16 inch) pin to hold the shaft in place.
3. Install the balance shaft chain and crankshaft sprocket.
4. Install the balance shaft tensioner and chain guide.
1 Install the balance shaft tensioner.
2 Install the balance shaft tensioner bolts.
3 Position the balance shaft chain guide and install the two bolts.
^ Remove the pin from the balance shaft tensioner.
Item 22: Oil Pump Assembly Note
1. Install the oil pump intermediate shaft, the oil pump, and the oil pump pick-up tube.
2. Install the oil pump drive assembly, the clamp, and the bolt.
Items 24-29: Lower Block Cradle, Gasket, and Bolts Assembly Note
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Clean and inspect the sealing surfaces.
2. NOTE: If the block cradle gasket is not secured within four minutes of the sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow the silicone to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone in the six places shown.
3. CAUTION: Failure to back off the set screws can result in damage to the lower block cradle.
NOTE: The set screw is shown from the top (crankshaft) side of the lower block cradle.
Back the set screws off until they are below the lower block cradle boss.
4. Position the lower block cradle and gasket assembly.
5. Install and hand-tighten the outer bolts and nuts.
6. Install and hand-tighten the rear lower block cradle bolts.
7. NOTE: The lower block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 inch) lower block cradle underflush or 0.05 mm (0.00196 inch) lower block cradle protrusion.
Using a straightedge, align the transmission face of the lower block cradle with the rear face of the cylinder block.
8. Tighten the outer bolts and nuts.
9. Tighten the rear lower block cradle bolts.
10. Tighten the eight inserts.
11. Install the two silver covered bolts and new washer seals. Hand-tighten them at this time.
12. Install and hand-tighten the six remaining bolts.
13. Tighten the lower block cradle bolts in two stages:
^ Stage 1: Tighten to 15 Nm(11 ft. lbs.).
^ Stage 2: Tighten to 34 Nm (25 ft. lbs.).
14. NOTE: Assemblies that measure out of specification must have the entire assembly procedure repeated.
Measure the step between the rear face of the cylinder block and the transmission face of the lower block cradle.
15. Repair all assemblies that exceed underflush specification by installing shims on one of both sides of the lower block cradle.