Part 1

Engine

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Special Tool(s) (Part 3):

Material (Part 1):

Material (Part 2):

Lower Components - 4.0L SOHC Engine (Part 1):

Lower Components - 4.0L SOHC Engine (Part 2):

Front and Rear Components - 4.0L SOHC Engine (Part 1):

Front and Rear Components - 4.0L SOHC Engine (Part 2):

Upper Components - 4.0L SOHC Engine (Part 1):

Upper Components - 4.0L SOHC Engine (Part 2):

Assembly (Steps 1-40)

CAUTION: If used as a leverage device, the fuel rail can be damaged. Care must be taken when working around the fuel rail.

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.

1. NOTE: Lubricate the crankshaft main bearings with clean engine oil before installation.

Install the crankshaft upper main bearings and the thrust bearing.

2. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance.

Install the crankshaft.





3. NOTE: The rear main bearing cap must be installed within 4 minutes after applying the silicone.

Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.





4. NOTE: Lubricate the crankshaft main bearings with clean engine oil before installation.

Install the crankshaft lower main bearings in the main bearing caps.
5. Install the main bearing caps.





6. Tighten the main bearing cap bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 35 Nm (26 ft. lbs).
^ Stage 2: Tighten an additional 57 degrees.





7. Lubricate the piston rings with clean engine oil.
8. Make sure that the piston rings are correctly spaced.
9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.





10. NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.

NOTE: Lubricate the cylinder wall with clean engine oil.

Using the special tool, install the pistons.





11. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.

Check the clearance of each connecting rod bearing.
12. Rotate the crankshaft until the piston is at the bottom of its stroke.

13. NOTE: For cylinders 1, 2 and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5 and 6, remove the opposite nut first.

Loosen the first nut until the face is approximately 2 mm (0.08 inch) over the end of the bolt.





14. Tap the bolt on the nut until it can be removed by hand.





15. Repeat previous 2 steps for the opposite bolt.
16. Install the new bolts, making certain that the bolt head is parallel to the sideward face of the connecting rod.





17. Install the connecting rod cap in the original position.
18. Install and tighten the connecting rod nuts finger tight.





19. Tighten the connecting rod nuts in 2 stages in pairs.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs).
^ Stage 2: Tighten an additional 90 degrees.
20. Repeat previous 4 steps for the remaining connecting rods.
21. Rotate the crankshaft until No. 1 piston is at top dead center (TDC).
22. Install the oil pump and the bolts.
^ Tighten to 19 Nm (14 ft. lbs).





23. Install the jackshaft.





24. Install the jackshaft thrust plate and the bolts.
^ Tighten to 11 Nm (8 ft. lbs).





25. Install the jackshaft spacer.





26. Install the oil pump drive and the hold down.
^ Tighten to 19 Nm (14 ft. lbs).





27. Position the RH camshaft drive cassette and install the sprocket bolt. Do not tighten the bolt at this time.





28. Install the RH camshaft drive cassette bolt and spacer.
^ Tighten to 18 Nm (13 ft. lbs).





29. Install the front cassette and bolt.
^ Tighten to 19 Nm (14 ft. lbs).





30. Position the jackshaft sprocket and chain.





31. Install the chain guide and bolts.
^ Tighten to 19 Nm (14 ft. lbs).





32. Install the chain tensioner and the bolts.
^ Tighten to 9 Nm (80 inch lbs).





33. Install the bolt. Do not tighten at this time.





34. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt.
^ Tighten to 20 Nm (15 ft. lbs).
35. Install the special tool on the rear of the jackshaft.





36. Tighten the rear bolt an additional 90 degrees.





37. Tighten the front bolt in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 ft. lbs).
^ Stage 2: Tighten 90 degrees.





38. Remove the special tool and install the rear jackshaft plug.





39. Position the front cover gasket and install the front cover and the fasteners.
^ Tighten to 19 Nm (14 ft. lbs).





40. CAUTION: Failure to back off the set screws can result in damage to the cylinder block cradle.

NOTE: The set screw is shown from the top (crankshaft) side of the cylinder block cradle.

Back the 8 set screws (7/16-inch Hex) off until they are below the cylinder block cradle boss.