Part 1

Engine








Special Tool(s)





Material

CAUTION: If the fuel supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.

NOTE: Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

1. NOTE: Lubricate the crankshaft main bearings with clean engine oil before installation.

Install the crankshaft upper main bearings and the thrust bearing.





2. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance.

Install the crankshaft.





3. NOTE: The rear main bearing cap must be installed within four minutes after applying the silicone.

Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.

4. NOTE: Lubricate the crankshaft main bearings with clean engine oil before installation.

Install the crankshaft lower main bearings in the main bearing caps.





5. Install the main bearing caps.





6. Tighten the main bearing cap bolts in two stages in the sequence shown .
1. Tighten bolts to 35 Nm (26 ft. lbs.).
2. Tighten bolts an additional 57 degrees.
7. Lubricate the piston rings with clean engine oil.
8. Make sure that the piston rings are correctly spaced.





9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.





10. NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.

NOTE: Lubricate the cylinder wall with clean engine oil.

Using the special tool, install the pistons.

11. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.

Check the clearance of each connecting rod bearing.
12. Rotate the crankshaft until the piston is at the bottom of its stroke.





13. NOTE: For cylinders 1, 2, and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5, and 6, remove the opposite nut first.

Loosen the first nut until the face is approximately 2 mm (0.08 inch) over the end of the bolt.





14. Tap the bolt on the nut until it can be removed by hand.
15. Repeat previous two steps for the opposite bolt.





16. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.
17. Install the connecting rod cap in the original position.





18. Install and tighten the connecting rod nuts finger tight.
19. Tighten the connecting rod nuts in two stages in pairs.
^ Stage 1: Tighten nuts to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten nuts an additional 90 degrees.
20. Repeat previous four steps for the remaining connecting rods.
21. Rotate the crankshaft until No. 1 piston is at top dead center (TDC).





22. Install the oil pump and the bolts.





23. Install the jackshaft.





24. Install the jackshaft thrust plate and the bolts.





25. Install the jackshaft spacer.





26. Install the oil pump drive and the hold down.





27. Position the RH camshaft drive cassette and install the sprocket bolt. Do not tighten the bolt at this time.





28. Install the RH camshaft drive cassette bolt and spacer.





29. Install the front cassette and bolt.





30. Position the jackshaft sprocket and chain.





31. Install the chain guide and bolts.





32. Install the chain tensioner and the bolts.





33. Install the bolt. Do not tighten at this time.
34. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt to 20 Nm (15 ft. lbs.).





35. Install the special tool on the rear of the jackshaft.





36. Tighten the rear bolt an additional 90 degrees.





37. Tighten the front bolt in two stages.
^ Stage 1: Tighten to 45 Nm (33 ft. lbs.).
^ Stake 2: Tighten 90 decrees.





38. Remove the special tool and install the rear jackshaft plug.





39. Position the front cover gasket and install the front cover.





40. CAUTION: Failure to back off the set screws can result in damage to the cylinder block cradle.

NOTE: The set screw is shown from the top (crankshaft) side of the cylinder block cradle.

Back the eight set screws (7/16-inch Hex) off until they are below the cylinder block cradle boss.





41. NOTE: If the cylinder block cradle gasket is not secured within four minutes of the sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow the metal surface cleaner to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone in the six places shown.





42. Position the cylinder block cradle and gasket assembly.





43. Install and hand-tighten the fifteen bolts and two nuts.





44. Install and hand-tighten the rear cylinder block cradle bolts.





45. NOTE: The cylinder block cradle to cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 inch) ladder frame underflush or mm (0.00196 inch) cylinder block cradle protrusion.

Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.





46. Tighten the fifteen bolts and two nuts.





47. Tighten the rear cylinder block cradle bolts.





48. Tighten the eight set screws (7/16-inch Hex).





49. Install new seals on the two silver bolts and position them in the cylinder block cradle.





50. Position the six remaining bolts.





51. Tighten the cylinder block cradle inner bolts in two stages in the sequence shown.
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 33 Nm (24 ft. lbs.).





52. NOTE: Assemblies that measure out of specification must have the entire assembly procedure repeated.

Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.





53. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the cylinder block cradle.





54. Install the oil pump screen cover and tube.





55. Install the gasket, and the oil pan.





56. Install the oil filter adapter.





57. Install the oil filter.





58. Install the coolant pump.





59. NOTE: LH shown, RH similar.

Install the cylinder head gaskets.





60. NOTE: LH shown, RH similar.

NOTE: Cylinder head bolts are a torque-to-yield design. New bolts must be installed.

Install the 12 mm (0.47 inch) bolts and tighten in the sequence shown.





61. NOTE: LH shown, RH similar.

Tighten the 12 mm (0.47 inch) bolts in two stages in the sequence shown.
1. Stage 1: Tighten bolts 80 degrees.
2. Stage 2: Tighten bolts an additional 80 degrees.