Part 1
EngineSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material (Part 1):
Material (Part 2):
Major Upper Engine Components:
Engine - Front Components:
Cylinder Heads and Valve Train (Part 1):
Cylinder Heads and Valve Train (Part 2):
Lower End Components (Part 1):
Lower End Components (Part 2):
Assembly (Steps 1-44)
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, may cause engine failure.
CAUTION: The moving components must be lubricated with clean engine oil before assembly, or the engine may be damaged.
CAUTION: The components with oil holes must be correctly aligned with the oil feed holes, or the engine may be damaged.
All vehicles
1. 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 old gasket.
NOTE: 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.
Clean all gasket mating surfaces in the following sequence. Use a plastic scraping tool, silicone gasket remover, if necessary and metal surface prep. Follow the directions on the packaging.
1 Remove any large deposits of silicone or gasket material with a plastic scraper.
2 Apply silicone gasket remover, following package directions and allow to set for several minutes.
3 Remove the silicone gasket remover with a plastic scraping tool. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4 Apply metal surface prep, following package directions, to remove any traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. If necessary, install the following:
1 Cylinder block dowels.
2 Oil gallery plugs.
3 Water jacket plugs.
3. Using the Camshaft Service Set, install the engine dynamic balance shaft bearings.
4. Using the Camshaft Service Set, install the camshaft bearings.
5. Install the following:
1 Engine dynamic balance shaft bearing cover
2 Camshaft bearing cover
6. If equipped, install the block heater.
^ Tighten to 2 Nm (18 lb-in).
7. CAUTION: Make sure the components are installed in the correct locations, or the engine may be damaged.
NOTE: Lubricate the crankshaft main bearings with clean engine oil prior to installation.
Install the 3 crankshaft upper main bearings and the crankshaft upper thrust main bearing.
8. CAUTION: Use care when installing the crankshaft, or the crankshaft bearing journals may be damaged.
Position the crankshaft.
NOTE: The main bearings are precision selective fit. Inspect the bearing clearance.
9. 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.
10. Install the 4 main bearing caps. Tighten the bolts in 2 stages.
^ Stage 1: Tighten to 55 Nm (41 lb-ft).
^ Stage 2: Rotate an additional 90 degrees.
11. Using a piston ring compressor, compress the piston rings.
12. CAUTION: Use care when installing the connecting rod and piston assemblies, or the cylinder wall may be damaged.
NOTE: Inspect the piston clearance.
Install the piston with the arrow on the piston face pointing toward the front of the engine.
13. CAUTION: Each connecting rod and connecting rod cap is a matched set. They will only fit together one way. Make sure the connecting rod cap is oriented correctly on the connecting rod or the engine may be damaged.
NOTE: Inspect the connecting rod bearing clearance.
Position the lower connecting rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal.
14. Tighten the 2 connecting rod cap bolts in 3 stages.
^ Stage 1: Tighten to 25 Nm (18 lb-ft).
^ Stage 2: Tighten to 45 Nm (33 lb-ft).
^ Stage 3: Tighten an additional 105 degrees.
15. Install the remaining pistons and the connecting rods.
16. Install the oil pan baffle and the 5 retaining nuts.
^ Tighten to 32 Nm (24 lb-ft).
17. Using a new gasket, position the oil pump screen cover and tube and install the 2 bolts and the nut.
1 Tighten the bolts to 25 Nm (18 lb-ft).
2 Tighten the nut to 32 Nm (24 lb-ft).
18. CAUTION: Use care when installing the camshaft or the camshaft lobes may be damaged.
Install the camshaft, camshaft spacer and camshaft key.
19. Install the camshaft thrust plate and 2 bolts.
^ Tighten to 11 Nm (8 lb-ft).
20. Install the engine dynamic balance shaft assembly and 2 bolts.
^ Tighten to 11 Nm (8 lb-ft).
21. NOTE: If correctly aligned, the engine dynamic balance shaft timing mark will be at the 6 o'clock position and the camshaft timing mark will be at the 12 o'clock position 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.
22. 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 12 valve tappets.
^ Install the tappet guide plates.
^ Install the 4 bolts and tighten to 12 Nm (9 lb-ft).
23. Install the timing chain tensioner and 2 bolts.
^ Position the timing chain tensioner.
^ Install the 2 bolts and tighten to 11 Nm (8 lb-ft).
24. If necessary, compress the tensioner pad and install a retaining pin.
25. Rotate the crankshaft so the No. 1 piston is at top dead center (TDC) and the keyway is at the 12 o'clock position.
26. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
27. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
28. 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, resulting in incorrect fuel injector timing and possible engine damage.
NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.
Make sure the timing marks and the keyways are aligned.
29. Remove the retaining pin.
30. Install the synchronizer drive gear and the bolt.
^ Tighten to 45 Nm (33 lb-ft).
31. NOTE: Use thread sealant with PTFE on studs No. 4 and 6 and bolt No. 12.
Install the engine front cover studs in their original locations.
^ Tighten the engine front cover studs to 7 Nm (62 lb-in).
32. NOTE: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
Using a new gasket, install the engine front cover.
^ Using a new gasket, install the coolant pump.
^ Tighten the fasteners in the sequence shown.
- Tighten capscrew No. 12 to 10 Nm (89 lb-in).
- Tighten all other fasteners to 28 Nm (21 lb-ft).
33. NOTE: Lubricate the crankshaft front seal with clean engine oil.
Using the special tools, install the crankshaft front seal.
34. Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper and use the special tool to install the crankshaft damper.
35. Using the special tool to prevent crankshaft rotation, install the bolt.
^ Tighten to 160 Nm (118 lb-ft).
36. 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 camshaft position (CMP) electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed and the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression stroke on the No. 1 cylinder. Failure to follow this procedure will result in incorrect fuel injector timing and possible engine damage.
CAUTION: A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in incorrect fuel injector timing and possible engine damage.
Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
37. 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 tool is 54 degrees from the centerline of the engine.
38. Install the camshaft synchronizer retaining bolt.
^ Tighten to 25 Nm (18 lb-ft).
39. Install the camshaft position (CMP) sensor and the 2 bolts.
^ Tighten to 6 Nm (53 lb-in).
40. NOTE: If the oil pan is not installed within 4 minutes, remove the sealant and reapply. Use silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.
1 Apply silicone gasket and sealant to the rear main bearing cap.
2 Install the oil pan rear seal.
3 Apply silicone gasket and sealant to the oil pan sealing surface.
41. NOTE: The 2 oil pan-to-engine front cover bolts are unique and must be installed in the correct positions.
Tighten the 17 oil pan bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).
42. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow this instruction may result in engine damage.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow this instruction may result in engine damage.
NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.
Using new gaskets, install the RH and the LH cylinder heads.
43. CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused. Failure to follow this instruction may result in engine damage.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the new bolts. Make sure the bolts are installed in the correct locations.
1 Install the new long bolts.
2 Install the new short bolts.
44. Tighten the bolts in the sequence shown in 3 stages.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten to 40 Nm (30 lb-ft).
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
