Steps 1-50

Engine


















Engine - Upper End














Engine - Lower End














Engine - Front End









1. 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 main bearings.

- Install the crankshaft upper main bearings into the cylinder block.

- Install the crankshaft lower main bearings into the bearing caps.

- Make sure all oil passages are aligned.

- Lubricate all main bearings with clean engine oil.

2. Lubricate the crankshaft bearing journals with clean engine oil. Install the crankshaft onto the upper crankshaft main bearings.





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

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





4. NOTE: Rotate the jackscrews into the main bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps.

Install the thrust washer on the rear (No. 5) main bearing cap and install the rear (No. 5) main bearing cap.





5. NOTE: Make sure the stud bolt is installed in the same position from which it was removed.

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 9 cap bolts and the stud bolt.

6. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.





7. Tighten the 9 vertical main bearing cap bolts and the stud bolt in the sequence shown, in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





8. Tighten the 10 jackscrews 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).





9. Install the 10 side bolts and tighten them in the sequence shown.
- Tighten to 21 Nm (15 lb-ft).





10. Check the crankshaft end play.

11. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).

12. Assemble the pistons. For additional information, refer to Piston Piston - Disassembly and Assembly.

13. Check the piston-to-cylinder block and piston ring clearances.

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





15. Make sure the dimple in the piston faces the front of the engine.





16. NOTICE: Install the piston and connecting rod assemblies carefully, or the cylinder walls or crankshaft journals may be damaged.

NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only one connecting rod, rod bearing and piston shown.

Use the Connecting Rod Installers and the Piston Ring Compressor to install the connecting rod with the upper connecting rod bearing in place.

- Lubricate the piston and ring with clean engine oil.

- Lubricate the rod bearings with clean engine oil.





17. NOTICE: Remove the Connecting Rod Installers carefully, or the crankshaft journals may be damaged.

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





18. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly, or the engine may be damaged.

NOTE: The connecting rod caps are of the "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.

19. NOTE: Main bearing caps removed from art for clarity.

Tighten the 16 bolts in 3 stages, in the sequence shown.

- Stage 1: Tighten to 23 Nm (17 lb-ft).

- Stage 2: Tighten to 43 Nm (32 lb-ft).

- Stage 3: Tighten an additional 105 degrees.





20. Position the oil pump and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





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





22. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring may 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 the O-ring with clean engine oil.

Position the oil pump screen and pickup tube and install the 3 bolts.

1. Tighten to 25 Nm (18 lb-ft).

2. Tighten to 10 Nm (89 lb-in).





23. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore, or the engine may be damaged.

NOTE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

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

NOTE: LH shown, RH similar.

Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 new cylinder head bolts loosely.





24. Tighten the 10 new LH cylinder head 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.





25. Tighten the 10 new RH cylinder head 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.





26. Install 8 new RH exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).





27. Install the new RH exhaust manifold gasket and the exhaust manifold. Tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).





28. 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 3 bolts.

- Apply threadlock to the bolt threads prior to installation.

- Tighten to 63 Nm (46 lb-ft).





29. 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 3 bolts.

- Apply threadlock to the bolt threads prior to installation.

- Tighten to 63 Nm (46 lb-ft).





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

NOTICE: 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 or engine damage may occur.

Compress the tensioner plunger, using a vise.





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





32. Remove the tensioner from the vise.

33. 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.





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





35. Install the timing chain guides.

1. Position the LH timing chain guide.

2. Install and tighten the 2 LH bolts.

3. Position the RH timing chain guide.

4. Install and tighten the 2 RH bolts.

- Tighten to 10 Nm (89 lb-in).





36. 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.





37. 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 Crankshaft Holding Tool.

Position the crankshaft so the No. 1 cylinder is at TDC with the Crankshaft Holding Tool.





38. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.





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





40. 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 and the 2 bolts.

- Tighten to 25 Nm (18 lb-ft).





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





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





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





44. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





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





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





47. Install the crankshaft sensor ring on the crankshaft.





48. NOTE: Camshaft roller follower is removed from art for clarity.

Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.





49. NOTICE: The camshaft roller followers must be installed in their original locations. Failure to follow this instruction 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. For additional information, refer to Engine Engine - Removal.

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 Valve Spring Compressor to compress the valve springs and install the camshaft roller follower.





50. Repeat the previous 2 steps for each camshaft roller follower.