Part 1
EngineSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material:
Engine - Lower Components (Part 1):
Engine - Lower Components (Part 2):
Engine - Upper Components (Part 1):
Engine - Upper Components (Part 2):
Engine - Front Components (Part 1):
Engine - Front Components (Part 2):
Cylinder Heads (Part 1):
Cylinder Heads (Part 2):
Engine - External Components:
Assembly (Steps 1-27)
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
CAUTION: The moving components must be lubricated with clean engine oil before assembly.
CAUTION: The components with oil holes must be correctly aligned with the oil feed holes.
1. If necessary, install the:
1 Cylinder block dowels
2 Oil gallery plugs
3 Coolant jacket plugs
2. Using the Camshaft Service Set, install the 2 engine dynamic balance shaft bearings.
3. Using the Camshaft Service Set, install the 4 camshaft bearings.
4. Install the:
1 Engine dynamic balance shaft bearing cover
2 Camshaft bearing cover
5. If equipped, install the block heater.
^ Tighten to 2 Nm (18 inch lbs).
6. CAUTION: Make sure the components are installed in the correct locations.
NOTE: Lubricate the crankshaft main bearings with clean engine oil prior to installation.
Install the 4 crankshaft upper main bearings and the crankshaft upper thrust main bearing.
7. CAUTION: The crankshaft journals must be protected from damage when installing the crankshaft.
Position the crankshaft.
CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance.
8. NOTE: If the rear main bearing cap is not installed within 4 minutes, remove the sealant and reapply.
Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket and sealant to the rear main bearing cap-to-cylinder block parting line.
9. Install the main bearing caps. Tighten the bolts in 2 stages.
^ Stage 1: Tighten to 55 Nm (41 ft. lbs).
^ Stage 2: Rotate an additional 90 degrees.
10. Using a piston ring compressor, compress the piston rings.
11. CAUTION: Inspect the piston clearance.
CAUTION: Do not damage the cylinder wall with the sharp edges of the connecting rod.
NOTE: 4.2L shown, 3.9L similar.
Install the piston with the arrow on the piston face pointing toward the front of the engine.
12. CAUTION: Inspect the connecting rod bearing clearance.
CAUTION: The connecting rod cap will fit only one way.
Position the lower connecting rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal.
13. Tighten the 2 connecting rod cap bolts in 3 stages.
^ Stage 1: Tighten to 25 Nm (18 ft. lbs).
^ Stage 2: Tighten to 45 Nm (33 ft. lbs).
^ Stage 3: Tighten an additional 105 degrees.
14. Install the remaining pistons and the connecting rods.
15. Install the oil pan baffle and the 5 retaining nuts.
^ Tighten to 32 Nm (24 ft. lbs).
16. Using a new gasket, install the oil pump screen cover and tube.
1 Tighten to 25 Nm (18 ft. lbs).
2 Tighten to 32 Nm (24 ft. lbs).
17. CAUTION: Do not damage the camshaft lobes when installing the camshaft.
Install the camshaft, camshaft spacer and camshaft key.
18. Install the camshaft thrust plate and 2 bolts.
^ Tighten to 11 Nm (8 ft. lbs).
19. Install the engine dynamic balance shaft assembly and 2 bolts.
^ Tighten to 11 Nm (8 ft. lbs).
20. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and the camshaft keyway will be at 6 o'clock on the camshaft.
Install the engine balance shaft drive gear so that the timing mark lines up with the timing mark on the engine balance shaft driven gear.
21. NOTE: Lubricate the valve tappets with clean engine oil prior to installing. If reusing the valve tappets, make sure to install them in their original locations.
Install the 12 valve tappets.
^ Install the valve tappets.
^ Install the tappet guide plates and retainers.
^ Install the bolts and tighten to 12 Nm (9 ft. lbs).
22. Install the timing chain tensioner and bolts.
^ Position the timing chain tensioner.
^ Install the bolts and tighten to 11 Nm (8 ft. lbs).
23. If necessary, compress the tensioner pad and install a retaining pin.
24. Rotate the crankshaft so the No. 1 piston is at top dead center (TDC) and the keyway is at the 12 o'clock position.
25. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
26. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
27. CAUTION: All timing marks must be aligned with the No. 1 cylinder set on 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.
Make sure the timing marks and the keyways are aligned.
