Steps 1-70

Engine

















Upper End - 4.0L SOHC Engine










Lower End - 4.0L SOHC Engine









All vehicles

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

NOTE: During engine assembly it may be necessary to check the bearing clearances and crankshaft end play.

NOTE: Before engine assembly, use silicone gasket remover and metal surface prep and a suitable plastic or wooden scraper to clean the sealing surfaces. Follow the directions on the packaging. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

1. Install the crankshaft main bearings and the thrust bearing.
- Lubricate the crankshaft main bearings with clean engine oil.





2. Install the lower main bearings in the bearing caps.

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

Install the crankshaft.





4. 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

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





5. Install the 4 main bearing caps in the same position from which they were removed.





6. Tighten the 8 bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 35 Nm (26 lb-ft).

- Stage 2: Tighten an additional 57 degrees.





7. Check the piston to cylinder bore and ring clearance.

8. NOTE: Lubricate the piston rings with clean engine oil.

Install the piston rings.

9. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.





10. Install the connecting rod bearings.





11. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.





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

Using the Piston Ring Compressor, install the pistons.

- Rotate the crankshaft as necessary.





13. 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.

14. Rotate the crankshaft until the piston is at the bottom of its stroke.

15. 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 in) over the end of the bolt.





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





17. Repeat the previous 2 steps for the opposite bolt.

18. Install the 2 new bolts, making certain that the bolt head is parallel to the sideward face of the connecting rod.





19. Install the connecting rod cap in the original position.

20. Install and tighten the 2 connecting rod nuts finger-tight.





21. Tighten the 2 connecting rod nuts in 2 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten an additional 90 degrees.

22. Repeat the previous 4 steps for the remaining connecting rods.

23. Rotate the crankshaft until the No. 1 piston is at Top Dead Center (TDC).

24. Install the balance shaft.

1. Install the balance shaft assembly.

2. Install the 2 bolts.
- Tighten to 29 Nm (21 lb-ft).





Early build vehicles

25. NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete turns of the balance shaft may be required to find the correct position.

Align the timing marks.

- Install a 4 mm (0.16 in) pin to hold the shaft in place.





Late build vehicles

26. NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete turns of the balance shaft may be required to find the correct position.

Align the timing marks.

1. Align the front balance shaft gear alignment marks with the hole in the balance shaft housing.

2. From the rear of the balance shaft, make sure the balance shaft gear alignment mark is visible through the hole in the balance shaft housing.





All vehicles

27. Install the balance shaft chain and crankshaft sprocket.





28. Install the balance shaft tensioner and chain guide.

1. Install the balance shaft tensioner.

2. Install the 2 bolts and tighten to 29 Nm (21 lb-ft).

3. Position the balance shaft chain guide, install the 2 bolts and tighten to 10 Nm (89 lb-in).

- Remove the pins from the tensioner and, if installed, the sprocket.





29. Install the oil pump intermediate shaft, the oil pump and the 2 bolts.
- Tighten to 19 Nm (168 lb-in).





30. Install the jackshaft.





31. Install the jackshaft thrust plate and bolts.
- Tighten to 11 Nm (97 lb-in).





32. Install the jackshaft spacer.





33. Install the oil pump drive and the hold down.
- Tighten to 19 Nm (168 lb-in).





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





35. Install the RH drive cassette bolt and spacer.
- Tighten to 18 Nm (159 lb-in).





36. Install the LH cassette and the bolt.
- Tighten to 19 Nm (168 lb-in).





37. Install the crankshaft key. Position the jackshaft and crankshaft sprockets and the chain.





38. Install the chain guide and the 2 bolts.
- Tighten to 19 Nm (168 lb-in).





39. Install the chain tensioner and the 2 bolts.
- Tighten to 9 Nm (80 lb-in).





40. Install the jackshaft sprocket bolt. Do not tighten the bolt at this time.





41. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt.
- Tighten to 20 Nm (177 lb-in).





42. Install the Rear Jack Shaft Socket on the rear of the jackshaft.





43. Using the Rear Jack Shaft Socket to hold the jackshaft, tighten the rear jackshaft bolt an additional 90 degrees.





44. Using the Rear Jack Shaft Socket to hold the jackshaft, tighten the front sprocket bolt in 2 stages.
- Tighten to 45 Nm (33 lb-ft).

- Tighten an additional 90 degrees.





45. Remove the Rear Jack Shaft Sprocket and install the rear jackshaft plug.





46. Position a new engine front cover gasket on the cylinder block.

47. NOTE: Apply thread sealant to the stud bolts and make sure that the stud bolts are installed in their original positions.

Position the front cover and loosely install the 5 bolts and the 5 stud bolts.





48. Install the Front Cover Aligner and tighten the 5 bolts and 5 stud bolts.
- Tighten to 19 Nm (168 lb-in).





49. NOTE: Lubricate the seal lip with clean engine oil.

Using the Front Cover Aligner and the Crankshaft Vibration Damper Installer, install the crankshaft front oil seal.





50. NOTICE: The cylinder block cradle inserts must be loosened completely or damage to the cylinder block cradle or oil leaks can result.

Loosen the 8 cylinder block cradle inserts.





51. 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in the 6 places shown.





52. Position the cylinder block cradle and a new gasket assembly.





53. Install and finger-tighten the 20 bolts and 2 nuts.





54. Install and finger-tighten the 2 Torx bolts.





55. NOTE: The cylinder block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle underflush or 0.05 mm (0.00196 in) cylinder block cradle protrusion.

Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.





56. Tighten the 20 bolts and the 2 nuts.
- Tighten the nuts to 10 Nm (89 lb-in).

- Tighten the bolts to 14 Nm (124 lb-in).





57. Tighten the Torx bolts.
- Tighten to 10 Nm (89 lb-in).





58. Tighten the 8 inserts.
- Tighten to 3 Nm (27 lb-in).





59. Install new seals on the 2 silver bolts and position them in the cylinder block cradle.





60. Position the 6 remaining bolts.





61. Tighten the 8 cylinder block cradle inner bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 15 Nm (133 lb-in).

- Stage 2: Tighten to 34 Nm (25 lb-ft).





62. NOTE: The cylinder block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle underflush or 0.05 mm (0.00196 in) cylinder block cradle protrusion.

Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.

- Cradles that exceed protrusion specification must be removed and the appropriate assembly steps repeated.

- Cradles that exceed the underflush specification may be repaired by installing shims (next step).





63. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the cylinder block cradle.





64. Install the oil pump screen cover and tube and the bolt.
- Tighten to 10 Nm (89 lb-in).





65. Install the gasket, the oil pan and the 10 bolts.
- Tighten to 11 Nm (97 lb-in).





66. Inspect and install new oil filter adapter O-ring seals if necessary.





67. Install the oil filter adapter and the bolt.
- Tighten to 57 Nm (42 lb-ft).





68. Install a new gasket, the coolant pump and the 13 bolts.
- Tighten to 10 Nm (89 lb-in).





69. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.





70. NOTE: A new bolt must be used each time it is removed.

Using the Strap Wrench, tighten the bolt in 2 stages.

- Stage 1: Tighten to 55 Nm (41 lb-ft).

- Stage 2: Rotate an additional 85 degrees.