Part 1

Engine

Special Tool(s):

Material:

Crankshaft, Camshaft and Piston:

Front Cover, Rear Cover and Oil Components (Part 1):

Front Cover, Rear Cover and Oil Components (Part 2):

Cylinder Head and Rocker Arm Carrier:

Valve Cover:

Assembly (Steps 1-33)

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

Install new D-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 Threadlock 262 to the threads prior to installation.

Install the 8 piston cooling tubes and bolts.
^ Tighten to 13 Nm (10 ft. lbs.).

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 and the thrust plate mounting bolts.
^ Tighten to 31 Nm (23 ft. lbs.).

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, all 20 lower crankcase main bearing mounting bolts and tighten the bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 122 Nm (90 ft. lbs.).
^ Stage 2: Tighten to 163 Nm (120 ft. lbs.).
^ Stage 3: Tighten to 231 Nm (170 ft. lbs.).

11. Install 8 M8 x 30 bolts around the outside of the lower crankcase and tighten the bolts in the sequence shown.
^ Tighten to 31 Nm (23 ft. lbs.).

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, all 20 lower crankcase main bearing mounting bolts and tighten the bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 122 Nm (90 ft. lbs.).
^ Stage 2: Tighten to 163 Nm (120 ft. lbs.).
^ Stage 3: Tighten to 231 Nm (170 ft. lbs.).

16. Install 8 M8 x 30 bolts around the outside of the lower crankcase and tighten the bolts in the sequence shown.
^ Tighten to 31 Nm (23 ft. lbs.).

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.
^ Tighten to 41 Nm (30 ft. lbs.).

21. Install the camshaft position (CMP) sensor and the bolt.
^ Tighten to 13 Nm (10 ft. lbs.).

22. Install the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 13 Nm (10 ft. lbs.).

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 keystone ring is identified with one indentation mark and a 15-degree keystone profile.
2 The intermediate compression ring is identified with 2 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 tighten the bolts in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 2: 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 tighten the bolts in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 2: Tighten to 68 Nm (50 ft. lbs.).

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

32. Install upper oil pan gasket, the upper oil pan and the bolts.
^ Tighten to 13 Nm (10 ft. lbs.).

33. 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.
^ Tighten to 13 Nm (10 ft. lbs.).