Steps 1-40
Engine
Engine Induction System
Engine - Upper End
Engine - Lower End
Engine - Front End
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, 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 2 intersect. This is the required bearing grade for the No. 1 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 4 main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings 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 main bearings.
- Install the crankshaft upper main bearings into the cylinder block.
- Install the crankshaft lower main bearings into the bearing caps.
- Make sure all oil passages are aligned.
- Lubricate all main bearings with clean engine oil.
6. Lubricate the crankshaft bearing journals with clean engine oil. Install the crankshaft onto the upper crankshaft main bearings.
7. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft thrust surface).
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
8. NOTE: Rotate the jackscrews into the main bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps.
Install the thrust washer on the rear (No. 5) main bearing cap and install the rear (No. 5) main bearing cap.
9. NOTE: Make sure the stud bolt is installed in the same position from which it was removed.
Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the 9 cap bolts and the stud bolt.
10. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.
11. Tighten the 10 vertical main bearing cap bolts and the stud bolt in the sequence shown, in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
12. Tighten the 10 crankshaft main bearing jackscrews against the cylinder block in the sequence shown in 2 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
13. Install the 10 side bolts and tighten them in the sequence shown.
- Tighten to 21 Nm (15 lb-ft).
14. Check the crankshaft end play. For additional information, refer to Engine System - General Information Camshaft End Play - OHC Engines.
15. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
16. Assemble the pistons. For additional information, refer to Piston Piston - Disassembly and Assembly.
17. Make sure the ring gaps (oil spacer-A, oil ring-B and compression ring-C) are correctly spaced around the circumference of the piston.
18. Make sure the dimple in the piston faces the front of the engine.
19. NOTICE: Install the piston and connecting rod assemblies carefully, or the cylinder walls or crankshaft journals may be damaged.
NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only one connecting rod, rod bearing and piston shown.
Use the Connecting Rod Installers and the Piston Ring Compressor to install the connecting rod with the upper connecting rod bearing in place.
- Lubricate the piston and ring with clean engine oil.
- Lubricate the rod bearings with clean engine oil.
20. NOTICE: Remove the Connecting Rod Installers carefully, or the crankshaft journals may be damaged.
Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installers.
21. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly, or the engine may be damaged.
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.
Position the lower bearing and connecting rod and install the new bolts loosely.
22. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to Engine System - General Information Camshaft End Play - OHC Engines.
23. NOTE: Main bearing caps removed from art for clarity.
Tighten the 16 bolts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 23 Nm (17 lb-ft).
- Stage 2: Tighten to 43 Nm (32 lb-ft).
- Stage 3: Tighten an additional 105 degrees.
24. Install the oil pump and loosely install the 3 bolts.
- Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
25. Install the pickup tube spacer.
- Tighten to 25 Nm (18 lb-ft).
26. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring may cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil.
Position the oil pump screen and pickup tube and install the 3 bolts.
1. Tighten to 25 Nm (18 lb-ft).
2. Tighten to 10 Nm (89 lb-in).
27. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore, or the engine may be damaged.
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 new cylinder head bolts loosely.
28. Tighten the 10 LH cylinder head bolts in 6 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Loosen all bolts a minimum of one full turn.
- Stage 4: Tighten to 40 Nm (30 lb-ft).
- Stage 5: Tighten an additional 90 degrees.
- Stage 6: Tighten an additional 90 degrees.
29. Tighten the 10 RH cylinder head bolts in 6 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Loosen all bolts a minimum of one full turn.
- Stage 4: Tighten to 40 Nm (30 lb-ft).
- Stage 5: Tighten an additional 90 degrees.
- Stage 6: Tighten an additional 90 degrees.
30. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
Install the 16 hydraulic lash adjusters in their original locations.
31. Install 16 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
32. Position the 2 new gaskets and the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 20 Nm (177 lb-in).
33. Position the 2 new gaskets and the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 20 Nm (177 lb-in).
34. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTICE: 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 or engine damage may occur.
Compress the tensioner plunger, using a vise.
35. Install a retaining clip on the tensioner to hold the plunger in during installation.
36. Remove the tensioner from the vise.
37. If the copper links are not visible, mark 1 link on one end and 1 link on the other end and use as timing marks.
38. Install the crankshaft sprocket, making sure the flange faces forward.
39. Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the 2 LH bolts.
- Tighten to 10 Nm (89 lb-in).
3. Position the RH timing chain guide.
4. Install and tighten the 2 RH bolts.
- Tighten to 10 Nm (89 lb-in).
40. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 1 o'clock position.
