Engine Assembly
Assembly Note
1. If necessary install the five pipe and core plugs.
2. Install the upper crankshaft main bearings.
3. Install the crankshaft.
Note
^ Coat the crankshaft main bearings with clean engine oil.
4. Install the crankshaft rear oil seal.
5. Install the lower crankshaft main bearings.
Note
^ Coat the crankshaft main bearings with clean engine oil.
6. Install the main bearing caps and lower bearings.
7. Install the main bearing cap bolts.
(1). Tighten the bolts in pairs in three steps.
^ Finger tighten the bolts.
^ Tighten the bolts to 68 - 81 Nm (6.9 - 8.3 kgf.m, 51 - 59 ft.lbs.).
^ Tighten the bolts to 102 - 115 Nm (10.4 - 11.7 kgf.m, 76 - 84 ft.lbs.).
8. Using the Connecting Rod Replacement Guides, install the piston and connecting rods.
Note
^ The connecting rods must be installed in their original position or engine damage may occur.
9. Install the connecting rod bearings.
Note
^ Coat the connecting rod bearings with clean engine oil.
10. Install the connecting rod caps.
11. Install the nuts.
(1). Tighten the nuts in pairs in three steps.
^ Tighten the nuts finger tight until flush with the bolts.
^ Tighten the nuts to 34 - 41 Nm (3.5 - 4.2 kgf.m, 26 - 30 ft.lbs.).
^ Tighten the nuts to 41 - 49 Nm (4.2 - 5.0 kgf.m, 31 - 36 ft.lbs.).
12. Repeat Steps 8 to 11 until all connecting rod assemblies are installed.
13. Install the front crankshaft seal and the gasket.
14. Install the front crankshaft seal retainer.
15. Install the oil pump screen cover and tube and the oil pump inlet tube gasket.
16. Apply a bead of Silicone Gasket and Sealant in six places.
^ Use Silicone Gasket and Sealant.
17. Position the oil pan gasket.
18. Position the oil pan.
19. Install the oil pan bolts.
^ Tighten the bolts in the sequence shown.
Note
^ Align the oil pan to the cylinder block using a straight edge.
^ The long bolts are installed in positions 15 and 18.
20. Install the coolant fitting.
21. Install the oil bypass filter.
22. Install the oil separator and 0-ring.
23. Clean head gasket sealing surfaces.
24. Install the head gasket.
25. Install the cylinder head assembly.
26. Install the bolts.
(1). Tighten the bolts in the sequence shown in two steps.
^ Tighten the bolts to 70 Nm (7.1 kgf.m, 52 ft.lbs.).
^ Tighten the bolts an additional 90 - 100 degrees.
27. Install the valve cover gasket.
28. Position the valve cover.
29. Install the valve cover bolts.
^ Tighten the bolts in the sequence shown.
30. Install the oil level indicator tube.
31. Connect the oil pressure sensor, the bulkhead connector and install the engine control sensor wiring.
32. Install the right and left ignition wire sets.
33. Connect the fuel injectors.
34. Install a new intake manifold upper gasket.
35. Position the upper intake manifold.
36. Connect the PCV valve and the coolant tube.
37. Install the bolts.
(1). Tighten the bolts in the sequence shown in two steps.
^ Tighten to 7 - 10 Nm (71 - 102 kgf.cm, 62 - 88 inch lbs.).
^ Tighten to 26 - 38 Nm (2.7 - 2.9 kgf.m, 20 - 28 ft.lbs.).
38. Connect the vacuum lines.
39. Install the EGR valve to exhaust manifold tube.
(1). Install the bolts.
(2). Connect the tube from the exhaust manifold.
40. Install the oil pump and the oil pump inlet tube gasket.
(1). If required, replace the oil pump.
(2). Install the oil pump inlet tube gasket.
41. Install the camshaft position sensor.
42. Install the timing belt shield.
43. Install the timing belt tensioner.
(1). Position the timing chain tensioner.
(2). Loosely install the tensioner pivot bolt.
(3). Position the tensioner arm fully clockwise.
(4). Snug the adjustment bolt.
44. Install the crankshaft position sensor.
45. Install the timing belt sprockets.
46. Align the sprockets to the timing marks.
47. Install the timing belt.
48. Loosen the bolt.
49. Rotate the crankshaft clockwise two complete revolutions and return to top dead center.
50. Confirm the timing marks have maintained alignment.
51. Tighten the bolts.
52. Using the crankshaft damper installer, install the crankshaft pulley.
53. Install the washer and bolt.
54. Install the timing belt cover.
55. Install the water hose connection.
(1). Replace the 0-ring it required.
(2). Position the water hose connection.
(3). Install the bolts.
56. Connect the vacuum line.
57. Connect the engine control sensor wiring to the:
^ idle air control valve
^ EGR transducer
^ throttle body
58. Connect the crankcase ventilation tube.
59. Install the water pump.
60. Install the water pump pulley.
61. Install the bolts.
62. Install the generator mounting bracket.
(1). Install the bolt.
(2). Install the bolt.
(3). Install the bolt finger-tight.
(4). Tighten all the bolts in sequence to 40 - 55 Nm (4.1 - 5.6 kgf.m, 34 - 40 ft.lbs.).
63. Connect the 8 spark plug wires.
64. Connect the engine control sensor wiring from the rear ignition coil.
65. Connect the engine control sensor wiring to the EGR solenoid and the radio ignition interference capacitor and the vacuum line to the EGR solenoid.
66. Connect the engine control sensor wiring to the crankshaft position sensor.
67. Connect the engine control sensor wiring to the:
^ engine coolant temperature sensor
^ water temperature indicator sender unit
^ forward ignition coil
68. Install the generator and the three bolts.
69. Connect the engine control sensor wiring to the generator.
70. Install the A/C compressor mounting bracket and the four bolts.
71. Install the drive belt.