Part 1

Engine

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Material (Part 1):

Material (Part 2):

Engine - Upper End (Part 1):

Engine - Upper End (Part 2):

Engine Induction System (Part 1):

Engine Induction System (Part 2):

Engine Lower End (Part 1):

Engine Lower End (Part 2):

Engine Front End (Part 1):

Engine Front End (Part 2):

Assembly (Steps 1-48)

1. Record the main bearing code found on the front of the engine block.





2. Record the main bearing code found on the crankshaft counterweight.





3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
^ Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
^ Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the number one crankshaft main bearing.
^ As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2".
^ Repeat this process for the remaining 4 main bearings.





4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.





5. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.

6. NOTE: The upper thrust washers are shown for location purposes only. Do not install the upper thrust washers until the crankshaft is installed. refer to the following 2 steps.

Install the crankshaft onto the upper crankshaft main bearings.





7. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).

Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the No. 5 upper main bearing.





8. NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps.

Install the rear main bearing cap.





9. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block, and keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
10. Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages:
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.





11. Tighten the jack screws against the cylinder block in the sequence shown, in 2 stages:
^ Stage 1: Tighten to 5 Nm (44 lb-in).
^ Stage 2: Tighten to 10 Nm (89 lb-in).





12. Install the side bolts and tighten them in the sequence shown.
^ Tighten to 21 Nm (15 lb-ft).





13. Assemble the 8 pistons.

14. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.

NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.

NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.

Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.





15. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.

Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.





16. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly. Failure to follow these instructions may result in engine damage.

NOTE: The connecting rod caps are of the 14 cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod, and install the new bolts loosely.

17. NOTE: Main bearing caps are removed for clarity.

Tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 43 Nm (32 lb-ft).
^ Stage 2: Tighten an additional 105 degrees.





18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





19. Install the pickup tube spacer.
^ Tighten to 25 Nm (18 lb-ft).





20. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-ring with clean engine oil.

Position the oil pump screen and pickup tube and install the bolts.
1 Tighten to 25 Nm (18 lb-ft).
2 Tighten to 10 Nm (89 lb-in).





21. NOTE: Clean and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts.
^ Tighten to 25 Nm (18 lb-ft).





22. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions 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 these instructions may result in engine damage.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused. Failure to follow these instructions may result in engine damage.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.





23. NOTE: RH shown, LH similar.

Tighten the bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.





24. Install 8 new RH exhaust manifold-to-cylinder head studs.
^ Tighten to 12 Nm (9 lb-ft).





25. Install the new RH exhaust manifold gasket and the exhaust manifold. Tighten the new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).





26. NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.

Position the RH engine support insulator and install the bolts.
^ Apply Threadlock(R) to the bolt threads prior to installation.
^ Tighten to 63 Nm (46 lb-ft).





27. NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.

Position the LH engine support insulator and install the bolts.
^ Apply Threadlock(R) to the bolt threads prior to installation.
^ Tighten to 63 Nm (46 lb-ft).





28. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Prior to installation, inspect the tensioner sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Failure to follow these instructions may result in engine damage.

Compress the tensioner plunger, using a vise.





29. Install a retaining clip on the tensioner to hold the plunger in during installation.





30. Remove the tensioner from the vise.
31. If the copper links are not visible, mark one link on one end and one link on the other end and use as timing marks.





32. Install the crankshaft sprocket, making sure the flange faces forward.





33. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install and tighten the LH bolts.
3 Position the RH timing chain guide.
4 Install and tighten the RH bolts.
^ Tighten to 10 Nm (89 lb-in).





34. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.





35. NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.

Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.





36. Remove the Crankshaft Holding Tool.
37. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.





38. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.





39. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
^ Tighten to 25 Nm (18 lb-ft).





40. Remove the retaining clip from the LH timing chain tensioner.





41. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.





42. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.





43. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
^ Tighten to 25 Nm (18 lb-ft).





44. Remove the retaining clip from the RH timing chain tensioner.





45. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.





46. Install the crankshaft sensor ring on the crankshaft.





47. NOTE: Camshaft roller follower is removed for clarity.

Install the special tool between the valve spring coils to prevent valve stem seal damage.





48. CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.

NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.

Use the special tool to compress the valve springs and install the camshaft roller follower.