Part 1
ENGINEAssembly
Warning:
^ Eye protection is required to be worn during the use of compressed air. Failure to wear eye protection could result in possible personal injury.
1. Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.
2. If removed, install the crankshaft key into the keyway on the crankshaft.
Note:
^ This procedure is for selecting bearings using a new crankshaft.
3. Select the crankshaft main bearings for each crankshaft journal.
a. Read the code on the crankshaft flange.
b. Read the code on the cylinder block rear face.
^ The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2.
^ The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.
4. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
^ For example: If the block code is *0609*0711* and the crankshaft code is *8480*8082*, main No. 1 should use grade 1 bearings, as deter mined by the intersection of the 06 block column and the 84 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
5. Install the main bearings into the cylinder block.
6. Install the main bearings into the lower cylinder block.
7. Install the crankshaft thrust bearing.
8. Apply SAE 5W-20 motor oil to the crankshaft main and rod bearing journals.
9. Position the crankshaft in the cylinder block.
Caution:
^ The lower cylinder block must be installed and the bolts tightened within four minutes of applying the sealant.
10. Apply Silicone Gasket and Sealant to the cylinder block as shown.
Caution:
^ Fasteners No 1, 5, 6, 7, 8 are studs. Fasteners No. 18 - 22 are M8 x 1 25 mm x 79.3 mm (0.05 inch x 3 12 inch) bolts. Fasteners No. 2 - 4, 17 are M8 x 1.25 mm x 95.3 mm (0.05 inch x 3.75 inch) bolts. Fasteners 9 - 16 are M10 x 1.5 mm x 106 mm (0.06 inch x 4.17 inch) bolts. The bolts and studs must be installed in the correct position or engine damage may result.
11. Position the lower cylinder block and install the bolts and studs
^ Tighten the bolts and studs in the sequence shown in four stages
^ Stage 1 Tighten fasteners 1 - 8 to 25 Nm (25 kgf-m, 18 ft. lbs.)
^ Stage 2 Tighten fasteners 9 - 19 to 40 Nm (41 kgf-m, 30 ft. lbs.)
^ Stage 3 Tighten fasteners 1 - 16 90 degrees
^ Stage 4 Tighten fasteners 17 - 22 to 25 Nm (25 kgf-m, 18 ft. lbs.)
12. Using the special tool, measure the crankshaft end play.
13. Using the special tool, install the crankshaft rear oil seal.
14. Position the flexplate and install the bolts.
15. Mount the engine on an engine stand.
16. Apply SAE 5W-20 motor oil to the cylinder bores.
17. Using the special tools, install the piston and connecting rod assemblies.
18. Check connecting rod bearing clearance.
19. Install the connecting rod caps and bolts.
^ Tighten the bolts in two stages.
^ Stage 1: Tighten to 23 Nm (2.3 kgf-m, 17 ft. lbs.).
^ Stage 2: Tighten to 43 Nm (4.4 kgf-m, 32 ft. lbs.).
20. Position the oil pump and install the bolts in the indicated sequence.
21. Position the oil pan baffle and install the nuts.
^ Tighten the nuts in two stages.
^ Stage 1: Tighten to 5 Nm (0.5 kgf-m, 44 in. lbs.).
^ Stage 2: Tighten 45 degrees.
22. Install a new O-ring seal on the oil pump screen and pick-up tube.
23. Install the oil pump screen and pick up tube.
a. Position the oil pump screen and pick up tube.
b. Install the bolts.
c. Install the nut.
^ Tighten the nut in two stages.
^ Stage 1: Tighten to 5 Nm (0.5 kgf-m, 44 in. lbs.).
^ Stage 2: Tighten 45 degrees.
24. Install the power steering/engine support bracket.
25. Install the oil separator.
^ Install the two bolts.
Note:
^ LH shown, RH similar.
26. Position the LH and RH cylinder heads, gaskets, and install the bolts.
^ Tighten the bolts in the sequence shown in six stages.
^ Stage 1: Tighten to 40 Nm (4.1 kgf-m, 30 ft. lbs.).
^ Stage 2: Tighten to 90 Nm (9.2 kgf-m, 66 ft. lbs.).
^ Stage 3: Loosen one full turn.
^ Stage 4: Tighten to 40 Nm (4.1 kgf-m, 30 ft. lbs.).
^ Stage 5: Tighten 90 degrees.
^ Stage 6: Tighten 90 degrees.
27. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o'clock position to locate Top Dead Center (TDC).
28. Apply SAE 5W-20 motor oil to the LH and RH camshaft followers.
Caution:
^ The camshaft followers must be installed in the original position.
Note:
^ RH shown, LH similar.
29. Install the LH and RH camshaft followers.
30. Apply SAE 5W-20 motor oil to the LH and RH camshafts.
31. Install the LH and RH camshafts.
^ Locate the camshafts as shown.
Caution:
^ Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.
32. Position the LH camshaft caps and install the bolts in the sequence shown.
33. Position the RH camshaft caps and install the bolts in the sequence shown.
34. Remove the crankshaft damper bolt.
35. Install the crankshaft sprockets.
Note:
^ LH shown, RH similar.
36. Position the chain tensioner in a soft-jawed vise.
Note:
^ LH shown, RH similar.
37. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
Caution:
^ During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
38. Slowly compress the timing chain tensioner.
39. Retain the tensioner piston with a 1.5 mm (0.06 inch) wire or paper clip.
40. If timing marks on the timing chains are not evident, use a permanent-type marker to mark on the LH and RH timing chains.
a. Mark any link to use as the crankshaft timing mark.
b. Counted links counterclockwise from the crankshaft timing mark (including the starting link) and mark this link as the (LH chain Exhaust RH chain Intake) cam sprocket timing mark.
c. Continue counting counterclockwise to 42 and mark this link as the (LH chain Exhaust RH chain Intake) sprocket timing mark.
41. Position the guide and install the bolts.
42. Install the LH timing chain.
a. Position number one on the crankshaft.
b. Count twenty-nine links from the number one link. Position on the exhaust cam sprocket.
c. Continue counting to forty-two and position link on intake sprocket timing mark.
43. Install the LH timing chain tensioner and tensioner arm.
a. Install the tensioner arm.
b. Position the tensioner.
c. Install the bolts.
44. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o'clock position.
45. Verify that the RH camshafts are correctly positioned.
46. Install the RH timing chain.
^ Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
47. Install the RH timing chain guide and install the bolts.
48. Install the RH timing chain tensioner and tensioner arm.
a. Install the tensioner arm.
b. Position the tensioner.
c. Install the bolts.
49. Remove the LH and RH timing chain tensioner piston retaining wires.
50. Remove the crankshaft damper bolt.
51. Verify the timing with the following steps.
a. There should be 12 chain links between the front camshaft timing marks.
b. There should be 27 chain links between the camshaft and crankshaft timing marks.
c. There should be 30 chain links between the camshaft and crankshaft timing marks.
52. Install the ignition pulse wheel.
Caution:
^ This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 20-25-34Y-30M (Color Blue).