Part 1
Engine
Assembly (Steps 1-30)
1. 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 main bearings.
^ Install the crankshaft upper main bearings into the cylinder block.
^ Install the crankshaft lower main bearings into the bearing caps.
^ Make sure all oil passages are aligned.
^ Lubricate all main bearings with clean engine oil.
2. Lubricate the crankshaft bearing journals with clean engine oil. Install the crankshaft onto the upper crankshaft main bearings.
3. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft thrust surface).
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
NOTE: Rotate the jackscrews into the main bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps
4. Install the thrust washer on the rear (No. 5) main bearing cap and install the rear (No. 5) main bearing cap.
5. 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.
6. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.
7. Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
8. Tighten the jackscrews against the cylinder block in the sequence shown in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 lb-in).
^ Stage 2: Tighten to 10 Nm (89 lb-in).
9. Install the side bolts and tighten them in the sequence shown.
^ Tighten to 21 Nm (15 lb-ft).
10. Check the crankshaft end play.
11. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
12. Check the piston-to-cylinder block and piston ring clearances.
13. Assemble the pistons.
14. Make sure the ring gaps (oil spacer-A, oil ring-B and compression ring-C) are correctly spaced around the circumference of the piston.
15. CAUTION: Install the piston and connecting rod assemblies carefully, or the cylinder walls or crankshaft journals may be damaged.
NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only one connecting rod, rod bearing and piston shown.
Use the special tools to 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.
16. CAUTION: Remove the special tools carefully, or the crankshaft journals may be damaged.
Once the connecting rod is seated on the crankshaft journal, remove the special tools.
17. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly, or the engine may be damaged.
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 new bolts loosely.
18. NOTE: Main bearing caps shown removed for clarity.
Tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 43 Nm (32 lb-ft).
^ Stage 2: Tighten an additional 105 degrees.
19. Position the oil pump and install the 3 bolts.
^ Tighten to 10 Nm (89 lb-in).
20. Install the pickup tube spacer.
^ Tighten to 25 Nm (18 lb-ft).
21. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring may 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.
Position the oil pump screen and pickup tube and install the bolts.
1 Tighten to 25 Nm (18 lb-ft).
2 Tighten to 10 Nm (89 lb-in).
22. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore, or the engine may be damaged.
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
NOTE: 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 special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 cylinder head bolts loosely.
23. Tighten the LH cylinder head bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.
24. Tighten the RH cylinder head bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.
25. Remove the special tool from the LH cylinder head.
26. Remove the special tool from the RH cylinder head.
27. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
Install the hydraulic lash adjusters into the RH and LH cylinder heads.
28. NOTE: Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
Install the LH and RH camshafts.
29. NOTE: LH shown, RH similar.
NOTE: Lubricate the camshaft bearing caps with clean engine oil.
Install the LH and RH camshaft bearing caps in their original locations.
^ Position the front camshaft bearing cap.
^ Position the remaining camshaft bearing caps.
^ Install the bolts loosely.
^ Tighten to 10 Nm (89 lb-in) in the sequence shown.
30. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE: LH shown, RH similar.
Position the camshaft phaser sprockets and install new camshaft phaser bolts finger-tight.
