Part 1
Engine
Crankshaft, Camshaft and Piston
Front Cover, Rear Cover and Oil Components
Cylinder Head and Rocker Arm Carrier
Valve Cover
Assembly
1. NOTE: Check alignment of the oil holes after installing the bearings.
If removed, using the Camshaft Service Set, install the new camshaft bearings.
2. NOTICE: The patch bolt is unique. Do not substitute or engine damage can occur.
NOTE: Apply threadlock to the threads prior to installation.
Install the 8 piston cooling tubes and 8 bolts.
- Tighten to 13 Nm (115 lb-in).
3. NOTICE: 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 2 thrust plate mounting bolts.
- Tighten to 31 Nm (23 lb-ft).
4. NOTE: Apply clean engine oil to all the bearings.
Install the new crankshaft upper bearings and the new crankshaft upper thrust bearing.
5. NOTE: Make sure the 2 dowels on the back of the camshaft alignment tool insert into the holes in the camshaft gear.
Install the Camshaft Alignment Tool, aligning the camshaft timing mark as shown.
6. NOTE: Apply clean engine oil to the crankshaft bearing journals prior to installing the crankshaft.
Install the crankshaft with the crankshaft timing peg in the slot in the Camshaft Alignment Tool, over the camshaft timing mark.
7. NOTE: Do not turn the crankshaft during the main bearing clearance check.
Position commercially available Plastigage(R) in the center of each main bearing bolt cap.
8. Install the new lower bearings into the lower crankcase.
9. NOTICE: 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 lb-ft).
- Stage 2: Tighten to 163 Nm (120 lb-ft).
- Stage 3: Tighten to 231 Nm (170 lb-ft).
10. Remove the 20 bolts and the lower crankcase.
11. Measure the clearances for the main bearings.
- Remove the Plastigage(R).
12. NOTE: Apply clean engine oil to the lower main bearings.
NOTE: Clean the groove and sealing surfaces of the upper and lower crankcase with metal brake parts cleaner or equivalent prior to applying the gasket maker.
NOTE: Make sure the gasket maker is used sparingly and spread to form a thin film on the surfaces.
Apply a thin film of gasket maker to the bottom of the groove and the sealing surfaces of the lower crankcase. Install the new lower crankcase seals on the film of gasket maker in the grooves of the lower crankcase. Apply a thin film of gasket maker on the upper crankcase sealing surfaces.
13. NOTICE: 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 lb-ft).
- Stage 2: Tighten to 163 Nm (120 lb-ft).
- Stage 3: Tighten to 231 Nm (170 lb-ft).
14. NOTICE: 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 Dial Indicator Gauge with Holding Fixture and measure the crankshaft end play.
15. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft end play.
16. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft gear backlash.
17. Install the block heater.
- Tighten to 41 Nm (30 lb-ft).
18. Install the Camshaft Position (CMP) sensor and the bolt.
- Tighten to 13 Nm (115 lb-in).
19. Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 13 Nm (115 lb-in).
20. NOTICE: 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 with clean engine oil.
Install the new connecting rod bearings.
21. NOTICE: 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.
22. 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 Piston Ring Compressor with clean engine oil.
2. Insert the piston into the Piston Ring Compressor. Position the piston, connecting rod and Piston Ring Compressor into the correct cylinder bore.
- Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.
23. Position a piece of Plastigage(R) across the bearing surface.
24. NOTICE: 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.
NOTE: Only one connecting rod cap shown.
Install the connecting rod cap and tighten the bolts in 2 stages.
- Stage 1: Tighten to 45 Nm (33 lb-ft).
- Stage 2: Tighten to 68 Nm (50 lb-ft).
25. Remove the bolts and the connecting rod cap.
26. Measure the clearances for the connecting rod cap.
- Remove the Plastigage(R).
27. NOTICE: 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.
NOTE: Only one connecting rod cap shown.
Install the connecting rod cap and tighten the bolts in 2 stages.
- Stage 1: Tighten to 45 Nm (33 lb-ft).
- Stage 2: Tighten to 68 Nm (50 lb-ft).
28. Using a Feeler Gauge Set, check for the minimum connecting rod side clearance.
29. Install new upper oil pan gasket, the upper oil pan and the 9 bolts.
- Tighten to 13 Nm (115 lb-in).
30. NOTICE: 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 guides and the 2 bolts.
- Tighten to 13 Nm (115 lb-in).
31. NOTE: RH shown, LH similar.
Position the high-pressure oil branch tube 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 high-pressure oil branch tube bolts to 14 Nm (124 lb-in).
32. Install the 4 new cylinder head dowels.
33. 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.
34. Using the Cylinder Head Lifting Bracket, install the cylinder heads.
35. Install the 10 outer head bolts finger-tight.
36. NOTICE: 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. The push rods are directional and the copper-coated end must be installed in the upward position where it will contact the rocker arm.
Apply clean engine oil to each end of the push rods and insert them into their respective positions.
37. NOTE: Coat the end of each valve stem with clean engine oil.
Install the 16 valve bridges.
38. NOTE: Left cylinder head shown, right cylinder head similar.
Install the new press-in-place gaskets, the rocker arm carriers and the 4 bolts.
- Tighten to 62 Nm (46 lb-ft).
39. 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 lb-ft).
40. NOTICE: 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 20 new cylinder head bolts finger-tight.
41. Tighten the head bolts in sequence in 7 stages:
- Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
- Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
- Stage 3: Tighten bolts 1 through 10 an additional 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 lb-ft).
- Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
42. NOTE: 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.
43. NOTICE: Failure to tighten the injector correctly can lead to engine failure.
NOTICE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
Assemble the fuel injector hold down and bolt on the fuel injector and install the assembly.
- Tighten to 35 Nm (26 lb-ft).
44. NOTICE: 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.
45. Apply clean engine oil to the top fuel injector O-ring seals.
46. NOTICE: 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: LH cylinder head shown, RH cylinder head similar.
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.
47. Remove the 3 guide bolts, install the 3 remaining high-pressure oil rail bolts and tighten the 9 high-pressure oil rail bolts in the sequence shown.
- Tighten to 13 Nm (115 lb-in).
48. Apply clean engine oil to the D-ring seals and reassemble the crankcase-to-head tube if necessary. Install the crankcase-to-head tubes.
- Tighten to 82 Nm (60 lb-ft).
49. Apply clean engine oil to the port plug seals and install the port plug in the high-pressure oil rail.
- Tighten to 82 Nm (60 lb-ft).
50. Connect the fuel injector electrical connectors.
