Part 1
EnginePart 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
Special Tool(s)
Assembly
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.
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.
NOTE: During engine assembly, it may become necessary to check bearing clearances and end play.
1. Read the first character code information on the cylinder block face (1) and record the information.
2. Read the first character on the No. 7 crankshaft counterweight and note it.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings chart determine the required bearing grade for each main bearing.
^ Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
^ Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing.
^ As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2".
^ Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings chart to determine the required bearing grade for each main bearing.
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
5. Illustration 1 of 19. Install the components in the order indicated.
Part 1 Of 2:
Part 2 Of 2:
6. Illustration 2 of 19. Install the components in the order indicated.
7. Illustration 3 of 19. Install the components in the order indicated.
8. Illustration 4 of 19. Install the components in the order indicated.
Part 1 Of 2:
Part 2 Of 2:
9. Illustration 5 of 19. Install the components in the order indicated.
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
10. Illustration 6 of 19. Install the components in the order indicated.
11. Illustration 7 of 19. Install the components in the order indicated.
12. Illustration - of 19. Install the components in the order indicated.
13. Illustration 9 of 19. Install the components in the order indicated.
14. Illustration 10 of 19. Install the components in the order indicated.
15. Illustration 11 of 19. Install the components in the order indicated.
16. Illustration 12 of 19. Install the components in the order indicated.
17. Illustration 13 of 19. Install the components in the order indicated.
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
18. Illustration 14 of 19. Install the components in the order indicated.
19. Illustration 15 of 19. Install the components in the order indicated.
20. Illustration 16 of 19. Install the components in the order indicated.
Part 1 Of 2:
Part 2 Of 2:
21. Illustration 17 of 19. Install the components in the order indicated.
22. Illustration 18 of 19. Install the components in the order indicated.
Part 1 Of 2:
Part 2 Of 2:
23. Illustration 19 of 19. Install the components in the order indicated.
Item 6: Crankshaft Main Lower Bearing Thrust Washer Assembly Note
1. CAUTION: Make sure the coated side of the thrust washer, with the 5 - mm wide oil grooves, faces the crankshaft thrust surface.
Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.
Items 7 - 10: Crankshaft Main Bearing Cap Assembly Note
1. Loosely install the main bearing caps and bolts.
2. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.
3. Tighten the bolts in the sequence shown in four stages:
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
^ Stage 3: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
Item 11: Crankshaft Main Bearing Cap Side Bolts Assembly Note
1. Install and tighten the cross - mounted bolts in two stages:
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
2. Check the crankshaft end play.
Item 13: Piston and Connecting Rod Assembly Assembly Note
1. Check the piston to cylinder block and piston ring clearances.
2. Position the piston rings as illustrated.
3. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: Make sure that the piston arrow is facing forward.
NOTE: The following piston installation steps are for all eight connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.
Using the special tools, install the connecting rod and piston with upper connecting rod bearing in place.
^ Lubricate the piston and ring with clean engine oil.
^ Lubricate the rod bearings with clean engine oil.
Item 15: Connecting Rod Caps Assembly Note
1. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.
NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
Position the lower bearing and connecting rod cap, and install the new bolts loosely.
Item 16: Connecting Rod Cap Bolts Assembly Note
1. NOTE: The rod bearing cap bolts are torque - to - yield designed. Install new bolts each time they are serviced.
Install the connecting rod bearing caps and bolts and tighten in three stages:
^ Stage 1: Tighten to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 3: Tighten an additional 90 degrees.
2. Check the connecting rod bearing clearance.
Items 20 and 23: RH and LH Cylinder Head Bolts Assembly Note
1. NOTE: The LH is shown; the RH is similar. NOTE: Lubricate the bolt heads and threads with clean engine oil.
Tighten the cylinder head bolts in six stages in the sequence shown:
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Loosen the bolts a minimum of one full turn.
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees.
^ Stage 6: Tighten an additional 90 degrees.
Items 38 - 46: Crankshaft Gear and Timing Chains Assembly Note
1. Install the crankshaft sprocket with the flange facing forward.
2. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and/or valve damage will occur.
Using the special tool, position the crankshaft.
^ Remove the special tool.
3. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is at approximately the 11 o'clock position.
4. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
5. install the LH and RH timing chain onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
6. NOTE: If necessary. adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the RH timing chain on the camshaft sprocket. Make sure the two copper - colored links align with the camshaft sprocket timing mark.
Items 42 and 45: Timing Chain Tensioner Assembly Note
1. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
^ Remove the retaining clip after installation.
Item 47: Crankshaft Sensor Ignition Pulse Ring Assembly Note
1. As a post - check, verify correct alignment of all timing marks.
2. Position the crankshaft sensor ring on the crankshaft.