Part 2
EngineAssembly (Steps 27-52)
27. Position a piece of Plastigage across the bearing surface.
28. Position the connecting rod cap and tighten the bolts in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 2: Tighten to 68 Nm (50 ft. lbs.).
29. Remove the bolts and the connecting rod cap.
30. Measure the clearances for the connecting rod cap. Remove the Plastigage.
31. Position the connecting rod cap and tighten the bolts in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 2: Tighten to 68 Nm (50 ft. lbs.).
32. Using a feeler gauge, check for connecting rod side clearance.
33. Install a new press-in-place gasket into the upper oil pan.
34. Position the upper oil pan and install the bolts.
^ Tighten to 13 Nm (10 ft. lbs.).
35. Install a new oil pickup tube O-ring seal.
36. Install the oil pickup tube and screen and the 2 bolts.
^ Tighten to 13 Nm (10 ft. lbs.).
37. 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 (10 ft. lbs.).
38. CAUTION: To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.
NOTE: Only the front guides use bolts.
Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guide and the bolts.
^ Tighten to 13 Nm (10 ft. lbs.).
39. NOTE: RH shown, LH similar.
Position the rear engine tube assembly and install the 2 bolts in 3 stages.
^ Stage 1: Tighten the RH bolt hand tight.
^ Stage 2: Tighten the LH bolt hand tight.
^ Stage 3: Tighten both rear engine tube assembly bolts to 13 Nm (10 ft. lbs.).
40. Install the 4 cylinder head dowels.
41. 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.
42. Using the special tool, install the cylinder heads.
1 Install the lifting bracket.
2 Install the bolts.
43. Install the 5 outer bolts for each cylinder head (finger tight).
44. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
NOTE: On early build vehicles, higher mileage engines require push rods to be cleaned so the copper-colored end of the push rod can be identified and installed with the copper-colored end up. Push rods on late build vehicles and service push rods do not have a copper-colored end and can be installed with either end up.
Apply clean engine oil to each end of the push rods and insert them into their respective positions.
45. NOTE: Coat the end of each valve stem with clean engine oil.
Install the 16 valve bridges.
46. Install the press-in-place gasket, the rocker arm carrier and the bolts.
^ Tighten to 31 Nm (23 ft. lbs.).
47. NOTE: Rotate the crankshaft until the damper locating dowel notch is in the 6 o'clock position.
NOTE: Apply clean engine oil to the top center of each valve bridge.
Install the rocker arm assemblies and the 16 bolts.
^ Tighten to 31 Nm (23 ft. lbs.).
48. CAUTION: Using too much engine oil on the threads of the cylinder head bolts, can 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 can affect the true torque value of the bolts.
NOTE: Early build engines will have 8 rocker arm carrier-to-cylinder head bolts. Late build will have 2 rocker arm carrier-to-cylinder head bolts.
NOTE: Early build shown, late build similar.
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 (finger tight).
49. Tighten the head bolts in 7 stages in the sequence shown:
^ Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 ft. lbs.).
^ Stage 2: Tighten bolts 1, 3, 5, 7 and 9 to 115 Nm (85 ft. lbs.).
^ Stage 3: Tighten bolts in sequence 1 through 10, 90 degrees.
^ Stage 4: Tighten bolts in sequence 1 through 10, a second time, 90 degrees.
^ Stage 5: Tighten bolts in sequence 1 through 10, a third time, 90 degrees.
^ Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 ft. lbs.).
^ Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 ft. lbs.).
50. CAUTION: If the fuel injector oil inlet O-ring is damaged, a new fuel injector must be installed.
NOTE: Lubricate the fuel injector and O-rings liberally with clean engine oil.
Install new O-rings and a copper washer on the fuel injector.
51. CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
Install the fuel injector, the fuel injector hold-down and bolt.
^ Tighten to 33 Nm (24 ft. lbs.).
52. CAUTION: Be sure the injector wiring is clear of all moving parts or engine damage can occur.
Install the fuel injector electrical connector into the rocker carrier.