Steps 1-60

Special Tool(s)





Material

Assembly





1. Record the main bearing code found on the front of the engine block.





2. Record the main bearing code found on the back of the crankshaft.





3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings chart, determine the required bearing grade for each main bearing.
^ Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
^ Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing.
^ As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is a "2."
^ Repeat this process for the remaining four main bearings.





4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings chart to determine the required bearing grade for each main bearing.





5. 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.





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





7. NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).

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





8. NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).

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





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

NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).

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.
10. 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, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.





11. Install the bolts.





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





13. 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 90 degrees.





14. 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 90 degrees.





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

16. 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.

17. 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.





18. 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 105 degrees.

19. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.





20. Install the oil filter adapter.
21. Install the cylinder block drain plugs.
22. Install the front engine support insulators.





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





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





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

Install the head gasket over the dowel pins.





26. Install the special tool.





27. NOTE: LH shown; RH similar.

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





28. Remove the special tool.





29. 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 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.





30. Install the oil level indicator tube.





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





32. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body, or permanent compression of the seal bead is observed, install a new tensioner.

Compress the tensioner plunger, using a vise.





33. Install a retaining clip on the tensioner to hold the plunger in during installation.
34. Remove the tensioner from the vise.





35. 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.





36. Install the timing chain guides.





37. 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.





38. CAUTION: Unless otherwise instructed, at no time when the timing chain is 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.
39. Remove the special tool.





40. Install the crankshaft sprocket, making sure the flange faces forward.





41. Install the lower end of the LH (inner) timing chain, aligning the timing marks.





42. NOTE: Make sure the upper half of the timing chain is below the tensioner guide dowel.

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

Position the timing chain on the LH camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned.





43. NOTE: Make sure the copper (marked) 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 crankshaft sprocket.





44. 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 (marked) links align with the camshaft sprocket timing mark.





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





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

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.





47. Remove the retaining clip from the LH timing chain tensioner.





48. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.





49. Remove the retaining clip from the RH timing chain tensioner.
50. Lubricate the balance shaft journals with clean engine oil.





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





52. Position the balance shaft on the journals.





53. Align the chalk mark on the balance shaft with the camshaft timing mark as shown.





54. Install the bearing caps in their original locations and install the bolts. Tighten the bolts in the sequence shown.
55. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.





56. Install the special tool between the valve spring coils to prevent valve stem seal damage.





57. NOTE: Lubricate the camshaft roller followers, using clean engine oil.

Install the camshaft roller followers.
1 Install the special tool.
2 Compress the valve spring.
3 Install the camshaft roller followers in their original locations.





58. Remove the special tool.





59. Position the crankshaft sensor ring.





60. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow 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 a bead of silicone gasket and sealant along the cylinder head-to-block surface and the oil pan-to-cylinder block surface as specified.