Part 1

Engine

Special Tool(s):

Special Tool(s):

Material:

Crankshaft, Camshaft and Piston (Part 1):

Crankshaft, Camshaft and Piston (Part 2):

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

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

Front Cylinder Head and Rocker Arm Carrier (Part 1):

Front Cylinder Head and Rocker Arm Carrier (Part 2):

Valve Cover:

Assembly

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 the crankcase-to-head tube assemblies.





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

If removed, use the special tool to install the camshaft bearings.





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

NOTE: Apply Threadlock 262 to the threads prior to installation.

Install the 8 piston cooling tubes and the 8 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 each bearing prior to installation.

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.

Position the lower crankcase and install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting 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. Remove the 20 bolts and the lower crankcase.





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





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

Install new lower crankcase seals.





14. 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.

Position the lower crankcase and install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting 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.).





15. Remove the bolt and special tool.





16. 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.

Using the special tool, measure the crankshaft end play.





17. Using the special tool, measure the camshaft end play.





18. Using the special tool, measure the camshaft gear backlash.





19. Install the block heater.
^ Tighten to 41 Nm (30 ft. lbs.).





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





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





22. CAUTION: The connecting rods are powdered metal cracked rods. Make sure the connecting rod and cap are installed as a set or engine damage can occur.

NOTE: Lubricate the connecting rod bearings with clean engine oil prior to installation.

Install the connecting rod bearings.





23. CAUTION: 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.





24. 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.





25. Position a piece of plastigage across the bearing surface.





26. CAUTION: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage can occur.

Position 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.).





27. Remove the bolts and the connecting rod cap.
28. Measure the clearances for the connecting rod cap. Remove the plastigage.





29. CAUTION: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage can occur.

Position 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.).





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





31. Install a new press-in-place gasket into the upper oil pan.





32. Position the upper oil pan and install the bolts.
^ Tighten to 13 Nm (10 ft. lbs.).





33. Install a new oil pickup tube O-ring seal.





34. Install the oil pickup tube and screen and the 2 bolts.
^ Tighten to 13 Nm (10 ft. lbs.).





35. Install the oil pan and the 20 bolts.
1 Install the 5 longer oil pan bolts.
2 Install the remaining oil pan bolts.
^ Tighten to 13 Nm (10 ft. lbs.).





36. 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.).





37. NOTE: RH shown, LH similar.

Position the rear engine tube assembly and install the 2 bolts in 3 stages.
^ Stage 1: Tighten the RH bolt hand tight.
^ Stage 2: Tighten the LH bolt hand tight.
^ Stage 3: Tighten both rear engine tube assembly bolts to 13 Nm (10 ft. lbs.).





38. Install the 4 cylinder head dowels.





39. NOTE: Install a new cylinder head gasket with the part number facing up. 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 gasket over the dowel sleeves and onto the crankcase.





40. Using the special tool, install the cylinder heads.
1 Install the lifting bracket.
2 Install the bolts.





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





42. 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.





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

Install the 16 valve bridges.





44. Install the press-in-place gasket, the rocker arm carrier and the bolts.
^ Tighten to 62 Nm (46 ft. lbs.).





45. 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.).





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: Left cylinder head shown, right cylinder head similar.

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

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





47. Tighten the head bolts in 7 stages in the sequence shown:
^ 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 in sequence 1 through 10, 90 degrees.
^ Stage 4: Tighten bolts in sequence 1 through 10, a second time, 90 degrees.
^ Stage 5: Tighten bolts in sequence 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.).





48. 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.





49. CAUTION: Failure to tighten the injector properly can lead to engine failure.

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.
^ Tighten to 35 Nm (26 ft. lbs.).