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).






26. Position the crankshaft keyway at the 11 o'clock position.

27. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.

NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry or engine damage may occur.

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 new cylinder head gaskets and cylinder heads over the dowels and install the 21 cylinder head bolts loosely.






28. Tighten the 21 bolts in 6 stages, in the sequence shown.
- Stage 1: Tighten the M12 fasteners to 25 Nm (18 lb-ft).

- Stage 2: Tighten the M12 fasteners to 60 Nm (44 lb-ft).

- Stage 3: Tighten the M12 fasteners an additional 90 degrees.

- Stage 4: Tighten the M12 fasteners an additional 90 degrees.

- Stage 5: Tighten the M8 fastener to 20 Nm (18 lb-ft).

- Stage 6: Tighten the M8 fastener and additional 45 degrees.






29. Using a small pick, carefully push the tensioner rack pawl retainer away from the rack pawl and compress the tensioner plunger and rack using a vise.





30. Install a small pick into the tensioner to hold the rack pawl and plunger in the seated position for tensioner installation.





31. Remove the tensioner from the vise.

32. If the blue links are not visible, mark 2 links on each end, and use as timing marks.





33. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel and above the chain guide pin.
Position the upper end of the LH (inner) timing chain on the LH camshaft phaser and sprocket, aligning the timing mark on the outer flange of the camshaft phaser and sprocket with the single blue (marked) link on the chain.






34. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single blue (marked) link on the chain and install the crankshaft sprocket onto the crankshaft and verify the crankshaft keyway is at the 11 o'clock position





35. Install the LH timing chain tensioner arm.





36. Position the LH timing chain tensioner and install the 2 bolts in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.






37. Position the LH timing chain guide and install the bolt in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.






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

39. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single blue (marked) chain link.





40. Position the upper end of the RH (outer) timing chain on the RH camshaft phaser and sprocket, aligning the timing mark on the outer flange of the camshaft phaser and sprocket with the single blue (marked) link on the chain.





41. Position the RH timing chain tensioner arm on the dowel pin and the RH timing chain tensioner and install the 2 bolts in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.






42. Position the RH timing chain guide and install the bolt in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.






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

44. As a post-check, verify correct alignment of all timing marks.





45. Lubricate the rocker arm shaft-to-valve tip and rocker arm-to-camshaft lobe contact area with clean engine oil prior to installation.

46. Rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully opened.

47. Position the LH intake rocker arm shaft assembly and install the bolts finger-tight.

48. Tighten the 10 LH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).

- Stage 3: Tighten an additional 60 degrees.






49. Rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully opened.

50. Position the LH exhaust rocker arm shaft assembly and install the bolts finger-tight.

51. Tighten the 10 LH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).

- Stage 3: Tighten an additional 60 degrees.






52. Rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully closed.

53. Position the RH intake rocker arm shaft assembly and install the bolts finger-tight.

54. Tighten the 10 RH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).

- Stage 3: Tighten an additional 60 degrees.






55. Rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully closed.