Steps 1-40
Engine
Engine - Lower Engine Block (View 1)
Lower Engine Block (View 2)
Engine - Front Engine Block
Engine - Cylinder Head
Engine - Intake Manifold
NOTICE: During engine repair procedures, cleanliness is extremely important. Foreign material, including any material created while cleaning gasket surfaces may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure.
NOTICE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley is loosened. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage may occur.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information Procedures.
All vehicles
1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.
NOTE: The front bulkhead does not have an oil squirter.
Install the 4 oil squirters.
- Tighten to 4 Nm (35 lb-in).
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
- Tighten the bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
5. Measure each crankshaft block main bearing bore diameter.
- Remove the bolts and the main bearing beam.
- Discard the main bearing beam bolts.
6. Using the chart, select the crankshaft main bearings.
7. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
Using the original connecting rod cap bolts, install the connecting caps and bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
- Remove the bolts and the connecting rod cap.
- Discard the connecting rod cap bolts.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
11. 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.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
NOTE: The center bulkhead is the thrust bearing.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.
Install and tighten the 10 main bearing beam bolts.
- Tighten the bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
- When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
- The position of the upper and lower compression ring gaps are not controlled for installation.
20. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
Install the connecting rod caps and bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
21. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) may result in damage to the engine.
NOTICE: Turn the crankshaft in the normal direction of rotation only, or the engine may be damaged.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
22. Remove the timing peg plug.
23. NOTE: The Crankshaft Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain in the TDC position during the crankshaft pulley removal and installation.
Install the Crankshaft Timing Peg.
24. NOTE: Clean the sealing surface with metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep.
Position the oil pump assembly and tighten the 4 bolts in the sequence shown, in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
25. NOTE: Clean the sealing surface with metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep.
Position a new oil pump pickup tube gasket and the pickup tube, and tighten the 4 bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
26. Using the Crankshaft Rear Main Oil Seal Installer, install the a new crankshaft rear seal and retainer plate assembly.
27. Tighten the 6 crankshaft rear seal and retainer plate assembly bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
28. NOTICE: 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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
NOTE: Clean the sealing surface with metal surface prep and silicone gasket remover. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep and the silicone gasket remover.
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. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the 13 oil pan bolts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
29. NOTICE: 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 the head 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 the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.
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 scraper. 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 remaining 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.
30. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head and the cylinder block distortion. For additional information, refer to Engine System - General Information Cylinder Head Distortion and Cylinder Block Distortion.
31. Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
32. NOTICE: 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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
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. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the locations shown.
33. Install a new cylinder head gasket.
34. 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. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
NOTE: Lubricate the cylinder head bolts with clean engine oil.
Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown, in 5 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Tighten an additional 90 degrees (one-fourth turn).
- Stage 5: Tighten an additional 90 degrees (one-fourth turn).
35. NOTICE: Install the camshafts with the alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position may cause severe damage to the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts and bearing caps in their original location and orientation. Tighten the 20 bearing cap bolts in the sequence shown in 3 stages:
- Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
- Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
- Stage 3: Tighten the bolts to 16 Nm (142 lb-in).
36. NOTICE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. The new diamond washers must be installed correctly, or severe engine damage may result.
Install the new diamond washers and the oil pump chain and sprockets.
- The crankshaft sprocket flange must be facing away from the engine block.
37. NOTE: The oil pump chain sprocket must be held in place.
Tighten the oil pump sprocket bolt.
- Tighten to 25 Nm (18 lb-ft).
38. Install the oil pump chain drive tensioner shoulder bolt.
- Tighten to 10 Nm (89 lb-in).
39. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt and tighten the tensioner bolt.
- Tighten to 10 Nm (89 lb-in).
40. NOTE: Sprockets must turn freely on the camshafts.
Position the camshaft sprockets and loosely install the bolts. Do not tighten the sprocket bolts at this time.
NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.