Part 2
EngineAssembly (Steps 34-66)
34. NOTE: Install a new cylinder head gasket with the part number facing upward. Verify the top 5 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 gaskets over the dowel sleeves and onto the crankcase.
35. Using the special tool, install the cylinder heads.
1 Install the lifting bracket.
2 Install the bolts.
^ Install the cylinder heads.
36. Install the 10 outer head bolts finger-tight.
37. 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.
Apply clean engine oil to each end of the push rods and insert them into their respective positions.
38. NOTE: Coat the end of each valve stem with clean engine oil.
Install the 16 valve bridges.
39. NOTE: Left cylinder head shown, right cylinder head similar.
Install the press-in-place gasket, the rocker arm carrier and the bolts.
^ Tighten to 62 Nm (46 ft. lbs).
40. NOTE: Rotate the crankshaft until the damper locating dowel notch is in the 6 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.
^ Tighten to 31 Nm (23 ft. lbs).
41. 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.
NOTE: Left cylinder head shown, right cylinder head similar.
Install the new cylinder head bolts finger-tight.
42. Tighten the head bolts in sequence in 7 stages:
^ Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 ft. lbs).
^ Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 ft. lbs).
^ Stage 3: Tighten bolts 1 through 10, 90 degrees.
^ Stage 4: Tighten bolts 1 through 10, a second time, 90 degrees.
^ Stage 5: Tighten bolts 1 through 10, a third time, 90 degrees.
^ Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 ft. lbs).
^ Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 ft. lbs).
43. CAUTION: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.
NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
Install new O-ring seals and a copper washer on the fuel injector.
44. CAUTION: Failure to tighten the injector correctly can lead to engine failure.
CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.
Install the fuel injector, the fuel injector hold-down and bolt.
^ Tighten to 35 Nm (26 ft. lbs).
45. CAUTION: Make 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.
46. Apply clean engine oil to the top fuel injector O-ring seals.
47. CAUTION: Using the bolts to push the high pressure oil rail into the fuel injectors can damage the fuel injectors and high pressure oil rail.
NOTE: Apply clean engine oil to the top fuel injector O-ring seals 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 4 single ball tubes are engaging the fuel injector lead angle.
^ Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
^ Manually 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 6 bolts.
48. Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
^ Tighten to 13 Nm (10 ft. lbs).
49. Apply clean engine oil and reassemble the crankcase-to-head tube. Install the crankcase-to-head tube.
^ Tighten to 82 Nm (60 ft. lbs).
50. Connect the fuel injector electrical connector.
51. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.
NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
Install the LH exhaust manifold and the bolts.
^ Tighten to 38 Nm (28 ft. lbs).
52. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.
NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
Install the RH exhaust manifold and the bolts.
^ Tighten to 38 Nm (28 ft. lbs).
53. Apply a bead of sealant at the back seam of the upper and lower crankcase.
54. Install the press-in-place gasket, the rear engine cover and the bolts.
^ Tighten to 24 Nm (18 ft. lbs).
55. NOTE: The crankshaft rear 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 Threadlock 262 around the circumference of the outer rear edge of the secondary crankshaft flange.
Using the special tools, install the crankshaft rear seal.
56. Install the flywheel adapter.
57. If removed, install the front cover crankcase dowels into the cylinder block.
58. Apply a bead of sealant at the front seam of the upper and lower crankcase.
59. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
Install the guide studs and the front cover gasket.
60. Install the engine front cover and the bolts.
^ Tighten to 24 Nm (18 ft. lbs).
61. NOTE: Install oil pump drive rotors with marks pointing outward.
Lubricate the inner drive rotor with a suitable lithium assembly grease and install onto the crankshaft. Lubricate the outer drive rotor with lithium assembly grease and mesh with the inner drive rotor in the oil pump housing. Wipe off excess assembly grease.
62. NOTE: Install a new O-ring seal.
Install the oil pump body and the 5 bolts.
^ Tighten to 13 Nm (10 ft. lbs).
63. NOTE: Apply Threadlock 262 to the outer circumference of the leading edge of the crankshaft.
NOTE: The seal and wear sleeve must not be separated.
Using the special tool, install the oil seal and wear sleeve assembly.
64. CAUTION: To prevent engine damage, always install 4 new bolts when installing the vibration damper.
NOTE: Do not use anti-seize compounds, grease or any lubricants. Lubricants have an adverse effect on the torque results.
Install the crankshaft vibration damper and tighten the new bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 68 Nm (50 ft. lbs).
^ Stage 2: Tighten an additional 90 degrees.
65. If equipped, install the dual generator pulley and the 3 bolts.
^ Tighten to 47 Nm (35 ft. lbs).
66. NOTE: Install a new O-ring seal on the coolant pump.
Install the coolant pump and the 4 bolts.
^ Tighten to 23 Nm (17 ft. lbs).
