Part 1
EngineSpecial Tool(s):
Material:
Major Upper Engine Components (Part 1):
Major Upper Engine Components (Part 2):
Cylinder block - Lower (Part 1):
Cylinder block - Lower (Part 2):
Assembly (Steps 1-39)
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 2 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 and tighten in the sequence shown.
^ Tighten to 80 Nm (59 ft. lbs).
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.
11. Install the camshaft.Install the camshaft retainer.
^ Tighten to 10 Nm (89 inch lbs).
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.
^ Tighten to 63 Nm (46 ft. lbs).
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 to 35 Nm (26 ft. lbs).
19. Install the oil pan baffle and nuts.
^ Tighten to 32 Nm (24 ft. lbs).
20. Install the oil pump and bolt.
^ Tighten to 48 Nm (35 ft. lbs).
21. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Install the hydraulic lash adjusters.
22. Install the hydraulic lash adjuster guide plates.
23. Install the hydraulic lash adjuster guide plate retainer.
^ Tighten to 12 Nm (9 ft. lbs).
24. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Install new head gaskets.
25. Install the cylinder heads.
26. Install the bolts. Tighten the bolts in the sequence shown in 5 stages.
^ Stage 1: Tighten to 50 Nm (37 ft. lbs).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 30 Nm (22 ft. lbs).
^ Stage 4: Tighten 90 degrees.
^ Stage 5: Tighten an additional 90 degrees.
27. Install a new oil filter.
28. NOTE: The end of the oil level tube should be cleaned with metal surface prep before application of the sealant.
Install the oil level indicator and tube assembly.
^ Coat the oil level indicator tube with silicone gasket and sealant.
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 thread sealant with PTFE on the bolts to be installed in the locations shown.
32. Install the 10 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
33. Install the knock sensor (KS) and bolt.
^ Tighten to 25 Nm (18 ft. lbs).
34. Install the crankshaft position (CKP) sensor and bolts.
^ Tighten to 10 Nm (89 inch lbs).
35. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
CAUTION: The thickness of the sealant must be between 4-6 mm (0.16-0.23 inch) or oil leaks could occur.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
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.
36. Position a new oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with the gasket clips.
37. NOTE: Make sure the fasteners are clean and dry prior to installation.
Install the oil pan and bolts. Tighten in the sequence shown.
^ Tighten to 12 Nm (9 ft. lbs).
38. Clean and inspect the exhaust manifolds.
39. Position a new exhaust manifold gasket and the LH exhaust manifold. Install new bolts and stud bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 10 Nm (89 inch lbs).
^ Stage 2: Tighten to 23 Nm (17 ft. lbs).
