Part 1

Engine











Special Tool(s)

Assembly





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 upper main bearings into the cylinder block and lubricate them with clean engine oil.





2. Install the crankshaft into the cylinder block and onto the upper crankshaft main bearings.





3. Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.





4. Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.





5. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.





6. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and tap into place using a plastic or dead-blow hammer.





7. Install the bolts.





8. Install the 10 dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.





9. Tighten fasteners 1 through 12 in two stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 85 degrees to 95 degrees.





10. Tighten fasteners 13 through 24 in two stages, in the sequence shown.
^ Stage 1: Tighten to 30 Nm (22 ft. lbs.).
^ Stage 2: Tighten an additional. 85 degrees to 95 degrees.





11. Using the special tools, install the piston and connecting rod assembly.

12. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Once the connecting rod is seated on the crankshaft journal, remove the connecting rod guide tools.

13. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.

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.

Install the connecting rod bearings, position the connecting rod cap and loosely install the two new bolts.





14. NOTE: Be sure to tighten the bolts in two stages.

Tighten the connecting rod bolts in the sequence shown.
^ Stage 1: Tighten to 43 Nm (32 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees to 120 degrees.
15. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.





16. Install the oil filter adapter.
17. Install the front engine support insulators.





18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.





19. Rotate the crankshaft to position the keyway at 12 o'clock.





20. NOTE: Do not turn the crankshaft until instructed to do so.

Install the head gasket over the dowel pins.





21. Install the special tool.





22. Install the special tool.





23. NOTE: LH shown; RH similar.

Install the cylinder head on the head gasket and loosely install the bolts.





24. Remove the special tool.





25. NOTE: Be sure to tighten the bolts in three stages.

Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 85 degrees to 95 degrees.
^ Stage 3: Tighten an additional 85 degrees to 95 degrees.





26. Install the oil level indicator tube.





27. Install the left and right exhaust manifold gaskets and exhaust manifolds. Loosely install the nuts. Tighten the nuts in the sequence shown.





28. Compress the tensioner plunger, using a vise.





29. Install a retaining clip on the tensioner to hold the plunger in during installation.





30. NOTE: There are 61 links in each timing chain.

If the copper links are not visible, mark two links on one end and one link on the other end to use as timing marks.





31. Loosen the special tool on both camshafts.





32. Install the timing chain guides.





33. Rotate the LH camshaft sprocket until the timing mark is approximately at 12 o'clock.
Rotate the RH camshaft until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Holding Tools to maintain camshaft pre-positioning. Specifications





34. CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston or valve damage can occur.

Position the crankshaft with the special tool.
35. Remove the special tool.





36. Install the crankshaft sprocket and lower end of the LH (inner) timing chain, aligning the timing marks.





37. NOTE: Make sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, use the Camshaft Holding Tool to adjust.

NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

Position the timing chain on the camshaft sprocket with the two copper chain links and the camshaft sprocket timing mark aligned.





38. CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured.

NOTE: Be sure the copper chain link and crankshaft sprocket timing mark are aligned.

NOTE: The lower half of the timing chain must be positioned above the dowel.

Position the RH (outer) timing chain on the camshaft sprocket.

39. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark.





40. As a post-check, verify timing mark alignment.





41. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole, for identification.

Position the LH and RH timing chain tensioner arm on the dowel pins. Position the timing chain tensioners, and install the bolts.





42. Remove both the RH and LH retaining clips from the timing chain tensioners.





43. Remove the special tool from the camshafts.
44. Lubricate the balance shaft journals with clean engine oil.





45. Using the index mark on the balance shaft, mark the corresponding teeth on the gear with chalk.