Steps 1-60

Special Tool(s)





Material

All vehicles





1. CAUTION: Install new O-ring seals on the crankcase-to-head tube. It requires several hours after installation for the O-ring seals to relax back to their original size. If the tube assembly is installed before the O-ring seals have relaxed, damage to the O-ring seals can occur.

Install new O-ring seals on each end of the crankcase-to-head tube assemblies.





2. NOTE: Check alignment of the oil holes after installing the bearings.

If removed, install the camshaft bearings.





3. CAUTION: The patch bolt is unique do not substitute or engine damage can occur.

NOTE: Apply high strength thread locker to the threads prior to installation.

Install the eight piston cooling tubes and bolts.





4. CAUTION: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage can occur.

NOTE: Apply clean engine oil to the camshaft prior to installing.

Install the camshaft and gear assembly. Install the thrust plate mounting bolts.





5. NOTE: Apply clean engine oil to all the bearings.

Install the crankshaft upper bearings and the crankshaft upper thrust bearing.





6. Using the special tool, align the camshaft timing mark as shown.





7. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.

8. NOTE: Do not turn the crankshaft during the main bearing clearance check.

Position commercially available plastigage in the center of each main bearing bolt cap.





9. Install the lower bearings into the lower crankcase.





10. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.

Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in the following sequence.
1 Tighten to 122 Nm (90 ft. lbs.) in numerical sequence.
2 Tighten to 163 Nm (120 ft. lbs.) in numerical sequence.
3 Tighten to 231 Nm (170 ft. lbs.) in the numerical sequence.





11. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.





12. Remove the 28 bolts and the lower crankcase.





13. Measure the clearances for the main bearings. Remove the plastigage.





14. NOTE: Apply clean engine oil to the lower main bearings.

Install new lower crankcase seals.





15. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.

Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten mounting bolts in the following sequence.
1 Tighten to 122 Nm (90 ft. lbs.) in numerical sequence.
2 Tighten to 163 Nm (120 ft. lbs.) in numerical sequence.
3 Tighten to 231 Nm (170 ft. lbs.) in the numerical sequence.





16. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.





17. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.

Install the special tool and measure the crankshaft end play.





18. Install the special tool and measure the camshaft end play.





19. Install the special tool and measure the camshaft gear backlash.





20. Install the block heater.





21. Install the Camshaft Position (CMP) sensor and the bolt.





22. Install the Crankshaft Position (CKP) sensor and the bolt.





23. NOTE: Lubricate with clean engine oil.

Install the connecting rod bearings.





24. NOTE: Make sure the ring openings are 120 degrees from each other, or engine damage can occur.

Install new piston rings.
1 The top compression ring is identified with one indentation mark and a 15 degree keystone profile.
2 The intermediate compression ring is identified with two indentation marks and a square profile.
3 Install the oil control ring.





25. NOTE: Cam V8 is toward the inside of the engine.

NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.

Install the piston and rod assemblies.
1 Coat the inside diameter of the ring compressor with clean engine oil.
2 Insert the piston into the special tool. Position the piston, connecting rod and special tool into the correct cylinder bore.
^ Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.





26. Position a piece of Plastigage across the bearing surface.





27. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
^ Tighten to 45 Nm (33 ft. lbs.).
^ Tighten to 68 Nm (50 ft. lbs.).

28. Remove the bolts and the connecting rod cap.





29. Measure the clearances for the connecting rod cap. Remove the plastigage.





30. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
^ Tighten to 45 Nm (33 ft. lbs.).
^ Tighten to 68 Nm (50 ft. lbs.).





31. Using a feeler gauge, check for connecting rod side clearance.





32. Install the upper oil pan.
^ Install the upper oil pan gasket.
^ Install the upper oil pan.
^ Install the bolts.





33. Install the oil pick-up tube and screen.
^ Install a new O-ring.
^ Install the oil pick-up tube and screen.
^ Install the bolts.





34. NOTE: Install a new press-in-place gasket.

Position the oil pan and install the bolts.
1 Install the longer oil pan bolts.
2 Install the remaining bolts.
^ Tighten to 13 Nm (10 ft. lbs.).





35. CAUTION: To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.

NOTE: Only the front guides use bolts.

Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guide and the bolts.

Early build vehicles





36. Install the rear engine tube assembly and the bolt.





37. Install the rear engine tube assembly bolts.

Late build vehicles





38. NOTE: RH side shown, LH side similar.

Install the rear engine tube assembly and bolts.
^ Position the rear engine tube assembly and install the right side bolt hand-tight.
^ Install the left side bolt hand-tight.
^ Tighten both rear engine tube assembly bolts.

All vehicles





39. Install the four cylinder head dowels.





40. NOTE: Install a new cylinder head gasket with the part number facing up. Verify the top five bolt holes and the head gasket push rod holes line up.

NOTE: Use care to avoid scratching the blue compound on the cylinder head gaskets.

Place the new cylinder head gasket over the dowel sleeves and onto the crankcase.





41. Using the special tool, install the cylinder heads.
1 Install the lifting brackets.
2 Install the bolts.
^ Install the cylinder heads.





42. Install the 5 outer bolts for each cylinder head (finger-tight).





43. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.

NOTE: Higher mileage engines require push rods to be cleaned so the copper colored end of the push rod can be identified.

Apply clean engine oil to each end of the push rod. Insert them into their respective position with the copper colored end up.





44. NOTE: Coat the end of each valve stem with clean engine oil.

Install the 16 valve bridges.





45. NOTE: Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position.

NOTE: Apply clean engine oil to the top center of each valve bridge.

Install the rocker arm assemblies and the 16 bolts.





46. CAUTION: Using too much engine oil on the threads of the cylinder head bolts, can cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads can affect the true torque value of the bolts.

NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.

Install the 10 new cylinder head retaining bolts for each cylinder head (finger-tight).





47. Tighten the head bolts in the following sequence.
1 Tighten bolts 1 through 10 to 88 Nm (65 ft. lbs.).
2 Tighten bolts 1, 3, 5, 7 and 9 to 115 Nm (85 ft. lbs.).
3 Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
4 Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
5 Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
6 Tighten bolts 11 through 15 to 24 Nm (18 ft. lbs.).
7 Tighten bolts 11 through 15 to 31 Nm (23 ft. lbs.).





48. CAUTION: To prevent engine damage, check that the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if these tubes are not bottomed out.

Apply clean engine oil and install a crankcase-to-head tube assembly.





49. CAUTION: If the fuel injector oil inlet O-ring is damaged, a new fuel injector must be installed.

NOTE: Lubricate the fuel injector and O-rings liberally with clean engine oil.

Install new O-rings and a copper washer on the fuel injector.





50. CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.

Install the fuel injector, the fuel injector hold-down and bolt.





51. CAUTION: Be sure the injector wiring is clear of all moving parts or engine damage can occur.

Install the fuel injector electrical connector into the rocker carrier.





52. NOTE: Apply clean engine oil to the top fuel injector O-rings before installing the high pressure oil rail.

Position the high pressure oil rail on the injectors.
^ Place the high pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle.
^ Insert three guide bolts, two on the ends of the straight side of the high pressure oil rail and one in the middle of the wavy side of the high pressure rail. Install the guide studs six to seven turns.
^ Press the high pressure oil rail into the fuel injectors.
^ Inspect that the high pressure oil rail mounting feet are flat against the mounting surface.
^ Loosely install the six bolts.





53. Install the remaining bolts and tighten.
^ Remove the three guide bolts.
^ Loosely install the three remaining bolts.
^ Tighten the nine bolts in the sequence shown.





54. Apply a bead of sealant at the back seam of the upper and lower crankcase.





55. Install the rear engine cover.
^ Install the press-in-place gasket.
^ Install the rear engine cover.
^ Install the bolts.





56. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.

NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant.

NOTE: Apply a bead of high strength thread locker around the circumference of the outer rear edge of the secondary crankshaft flange.

NOTE: The rear main seal and wear sleeve are correctly seated when the crankshaft begins to rotate.

Using the special tools, install the crankshaft rear oil seal.





57. Install the flywheel adapter.





58. If removed, install the front cover crankcase dowels into the cylinder block.





59. Apply a bead of sealant at the front seam of the upper and lower crankcase.





60. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.

Install the guide studs and the front cover gasket.