Assembly
ASSEMBLYEngine
Special Tools And Equipment:
Special
Material:
Material
All vehicles
1. Install the crankshaft upper main bearings.
2. NOTE: Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
Install the crankshaft.
3. NOTE: Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with clean engine oil.
Install the crankshaft rear oil seal.
4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block.
5. Install the crankshaft lower main bearings.
6. Install the main bearing caps.
7. Wedge a large screwdriver at the location shown to hold the crankshaft forward until all the bolts are tightened.
8. Install the bolts.
^ Tighten the bolts in pairs.
9. If removed, install the camshaft bearings.
^ Use the Camshaft Service Set.
10. NOTE: Lubricate the camshaft and the camshaft bearings with clean engine oil.
Install the camshaft.
11. Install the camshaft retainer.
12. Inspect the camshaft end play.
13. Align the timing marks.
14. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
15. Install the bolt.
16. NOTE: Lubricate the piston and connecting rod assemblies with clean engine oil.
Install the piston and connecting rod assemblies.
^ Use a piston ring compressor.
17. NOTE: Lubricate the connecting rod bearings with clean engine oil.
Install the connecting rod bearings.
18. Install the connecting rod caps and nuts.
^ Tighten the nuts in pairs.
19. Install the oil pan baffle.
20. Install the oil pump.
21. NOTE: Lubricate the valve tappets with clean engine oil.
Install the valve tappets.
22. Install the valve tappet guide plates.
23. Install the valve tappet guide plate retainer.
24. Install new head gaskets.
25. Install the cylinder heads.
26. Install the bolts. Tighten the bolts in the sequence shown in four steps.
1 Tighten the bolts to 80 Nm (59 ft. lbs.).
2 Loosen the bolts one full turn.
3 Tighten to 50 Nm (37 ft. lbs.).
4 Tighten to 92 Nm (68 ft. lbs.).
27. Install the oil bypass filter.
28. Install the oil level indicator tube.
29. CAUTION: All timing marks must be aligned with the No. 1 cylinder set on top dead center (TDC)of the compression stroke or the synchronizer assembly will not be installed correctly.
NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.
Align the timing marks.
30. Install a new engine front cover gasket and the engine front cover.
31. Apply pipe sealant with Teflon on the bolts to be installed in the locations shown.
32. Install the bolts.
33. Install the Crankshaft Position (CKP) sensor.
34. CAUTION: The thickness of the sealant must be between 4 - 6 mm (0.16 - 0.23 inch) or oil leaks could occur.
NOTE: The oil pan should be installed and tightened to specification within four minutes of the sealant application or oil leaks can occur.
Apply a 4.0 - 6.0 mm (0.16 - 0.23 inch) bead of silicone gasket and sealant to the junction of the rear main bearing cap and the cylinder block, and to the junction of the front cover assembly and cylinder block.
35. Position the oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with the gasket clips.
36. NOTE: Make sure the fasteners are clean and dry prior to installation.
Tighten the oil pan bolts to 12 Nm (9 ft. lbs.) in the sequence shown.
CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from TDC of the compression stroke on the No. 1 cylinder.
37. CAUTION: A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.
Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
38. NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.
NOTE: During installation, the arrow on the special tool will rotate clockwise as the gears engage.
Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment gauge is 38 degrees from the centerline of the engine.
39. Install the camshaft synchronizer retaining bolt.
40. Install the Camshaft Position (CMP) sensor.
41. Apply four beads of silicone gasket and sealant.
42. Install the intake manifold gaskets and end seals.
^ Position the intake manifold gaskets.
^ Position the end seals.
43. Install the lower intake manifold.
^ Tighten the bolts in the sequence shown.
44. Install the push rods and the rocker arms.
^ Install the push rods.
^ Install the rocker arms.
^ Tighten the rocker arm bolts.
45. Apply a bead of silicone gasket and sealant to the four intake to cylinder head seams.
46. If removed, install the valve cover gaskets.
47. Install the valve covers and bolts
^ Tighten the bolts in the sequence shown.
48. Position the engine control sensor wiring and connect:
^ the CMP sensor.
^ the fuel injectors.
^ the water temperature indicator sender unit.
^ the engine control sensor wiring.
49. Using the Crankshaft Vibration Damper Installer, install the crankshaft damper.
50. Install the bolt.
51. Install the crankshaft vibration damper and the bolts.
52. Install the coolant pump pulley and the bolts.
53. Install the generator mounting bracket and the bolts.
54. Position the ignition coil assembly and install the bolts.
55. Connect the ignition coil.
56. Connect the spark plug wires.
57. Install the Lifting Eyes and the lifting equipment.
58. Remove the engine from work stand.
59. Install the engine-to-transmission spacer plate.
60. Install the flywheel or flexplate.
Vehicles equipped with a manual transmission
61. Adjust the clutch pressure plate.
1 Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2 Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3 Release the pressure on the fingers. The adjusting ring will stay in the reset position.
62. Using the special tool, position the clutch disc on the flywheel.
63. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern.