Part 1
Engine
Engine - Upper End
Engine - Front End
Engine - Lower End
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 No. 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. Position the 4 piston oil cooler valves with the bolt boss facing toward the rear of the cylinder block and install the 4 bolts in 2 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.
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. NOTICE: Do not allow the crankshaft to come into contact with the piston oil cooler valves during assembly or engine damage may occur.
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.
8. Install the lower crankshaft flange bearing onto the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
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. Install the 20 vertical inner and outer main bearing cap fasteners and the main bearing side bolts finger-tight.
11. Apply a forward load to the crankshaft, so that the crankshaft thrust face is seated.
12. Tighten the 10 vertical outer main bearing cap fasteners in 3 stages, in the sequence shown.
- Stage 1: Tighten to 35 Nm (26 lb-ft).
- Stage 2: Tighten to 50 Nm (26 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
13. Tighten the 10 vertical inner main bearing cap fasteners in 3 stages, in the sequence shown.
- Stage 1: Tighten to 35 Nm (26 lb-ft).
- Stage 2: Tighten to 65 Nm (48 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
14. Install the 10 side bolts and tighten them in 3 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 35 Nm (26 lb-ft).
- Stage 3: Tighten an additional 60 degrees.
15. Check the crankshaft end play clearance.
16. Assemble the 8 pistons. For additional information, refer to Piston .
17. Make sure the ring gaps (upper compression ring- A, oil control segment ring- B, expander ring and lower compression ring- C) are correctly spaced around the circumference of the piston.
18. NOTICE: Do not allow the connecting rod to come into contact with the piston oil cooler valves during assembly or engine damage may occur.
NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only one connecting rod, rod bearing and piston is shown.
NOTE: The arrow on the top of the piston faces the front of the engine.
Using the Piston Ring Compressor and the Connecting Rod Installer, 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.
19. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
20. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
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 16 new bolts loosely.
21. Check the piston-to-cylinder block and piston ring clearances.
22. NOTE: Main bearing caps are removed for clarity.
Tighten the 16 bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 43 Nm (32 lb-ft).
- Stage 3: Tighten an additional 135 degrees.
23. Position the oil pump and install the 2 upper bolts and the lower stud bolts in 5 stages.
- Stage 1: Tighten all fasteners to 2 Nm (18 lb-in).
- Stage 2: Tighten the 2 upper bolts to 10 Nm (89 lb-in).
- Stage 3: Tighten the 2 lower stud bolts to 20 Nm (177 lb-in).
- Stage 4: Tighten the 2 upper bolts an additional 45 degrees.
- Stage 5: Tighten the 2 lower stud bolts an additional 60 degrees.
24. NOTICE: 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 the O-ring with clean engine oil prior to installation.
Position the oil pump screen and pickup tube and install the 2 front bolts.
- Tighten to 10 Nm (89 lb-in).
25. Install the oil pump screen and pickup tube support bracket nut.
- Tighten to 24 Nm (18 lb-ft).
