Part 1

Engine

















Engine Intake Components









Low End Components













Upper End Components













Major Exterior Components













Assembly

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





2. Record the main bearing code found on the back of the crankshaft.





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 1 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: 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.





7. Install the crankshaft into the cylinder block and onto the upper crankshaft main bearings.





8. NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).

Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.





9. NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).

Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.





10. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

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

Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.





11. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.

12. Install the 12 bolts.





13. Install the 12 dowel pins so that the flat sides face the crankshaft. Install the 12 cross-mounted bolts.





14. Tighten fasteners 1 through 12 in 2 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





15. Tighten fasteners 13 through 24 in 2 stages, in the sequence shown.
- Stage 1: Tighten to 30 Nm (22 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





16. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to Engine.

17. Assemble the 10 pistons. For additional information, refer to Piston Piston - Disassembly and Assembly.

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





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





20. NOTICE: Install the pistons 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 Guides and Piston Ring Compressor to install the connecting rod with the upper connecting rod bearing in place.

- Lubricate the piston, connecting rod bearing and rings with clean engine oil prior to installation.





21. NOTICE: 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 Guides.





22. NOTICE: 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 "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Install the connecting rod bearings, position the connecting rod caps and loosely install the 2 new bolts for each connecting rod.

- Lubricate the connecting rod bearing with clean engine oil prior to installation.

23. NOTE: Be sure to tighten the bolts in 2 stages.

Tighten the connecting rod bolts in the sequence shown.

- Stage 1: Tighten to 43 Nm (32 lb-ft).

- Stage 2: Tighten an additional 105 degrees.





24. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.

25. Position the oil filter adapter gasket and the oil filter adapter. Install the nut and the 4 bolts.
- Tighten the front bolts to 25 Nm (18 lb-ft).

- Tighten the rear nut to 48 Nm (35 lb-ft).





26. Position the oil pump and install the 3 bolts loosely. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





27. Position the crankshaft with the keyway at the 12 o'clock position.





28. NOTICE: 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.

NOTICE: 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.

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

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 loosely install the 20 cylinder head bolts.





29. NOTE: Be sure to tighten the bolts in 3 stages.

Tighten the bolts in 3 stages.

- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Tighten an additional 90 degrees.

- Stage 3: Tighten an additional 90 degrees.





30. Install the insert into the LH cylinder head.





31. Position the oil level indicator tube and install the nut.
- Tighten to 25 Nm (18 lb-ft).





32. Install the bolt attaching the oil level indicator tube to the LH cylinder head.
- Tighten to 10 Nm (89 lb-in).





33. NOTE: LH shown, RH similar.

Install 20 new exhaust manifold studs.

- Tighten to 12 Nm (106 lb-in).





34. Position a new gasket, the RH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).





35. Position a new gasket, the LH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).





36. 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.





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





38. NOTE: There are 61 links in each timing chain.

If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.





39. Install the timing chain guides and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





40. Preposition the LH camshaft until the timing mark is approximately at 12 o'clock and preposition the RH camshaft until the timing mark is approximately at 11 o'clock.





41. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.





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





43. Install the lower end of the LH timing chain, aligning the timing marks.





44. NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.

Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.





45. 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 2 bolts.

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





46. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

NOTE: The lower half of the timing chain must be positioned above the dowel.

Install the RH (outer) timing chain on the crankshaft sprocket.





47. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.





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





49. Remove the retaining clips from the RH and LH timing chain tensioners.





50. Check for correct alignment of all timing marks.