Steps 1 - 12

1. Cylinder Block Plug Installation:
a. Install the engine block coolant drain plugs.
^ Apply gasket paste to the plugs before installation.
^ Coolant Jacket Plugs to 15 Nm (11 ft. lbs.).
b. Install the cooling jacket core plugs.
c. Apply gasket paste to the plugs before installation
d. Drive the plugs into the block until they are flush using a drift that closely matches the inside diameter of the plug.





2. Crankshaft, Bearings, and Bearing Cap Installation:
a. Apply engine oil to the main bearing inserts.
b. Install the upper main bearing inserts.
c. Install the crankshaft.
d. Install the lower main bearing inserts to the main bearing caps.
^ Make sure that the inserts are the correct size.
^ Apply engine oil to the inserts.
e. Measure the main bearing clearance.
f. Install the main bearing caps to the engine block.





g. Install the main bearing cap bolts to the engine block.
^ Tighten the main bearing cap bolts first to 50 Nm (37 ft. lbs.).





h. Measure the crankshaft end play using the following procedure:
1. Firmly thrust the crankshaft rearward.
2. Firmly thrust the crankshaft forward.
3. This will align the main bearing and the crankshaft thrust surfaces.
^ Tighten the main bearing cap bolts to 95 Nm (70 ft. lbs.).





i. Measure the crankshaft end play at the front end of the rear main bearing with a feeler gauge.
^ The crankshaft should still be wedged forward.
^ The proper clearance is 0.0511 - 0.1780 mm (0.002 - 0.007 inch).





3. Crankshaft Rear Oil Seal and Housing Installation:
Tools Required: J34686 Rear Main Bearing Oil Seal Installer, or equivalent.
a. Install the crankshaft rear oil seal.
b. Lubricate the seal bore to seal mating surface with engine oil.
c. Slide a new crankshaft rear oil seal onto tool J 34686. The dust lip of the crankshaft rear oil seal should be flush against the J 34686 tool collar.
d. Align the dowel pin of the tool J 34686 with the dowel pin hole in the crankshaft.
e. Attach tool J 34686 to the crankshaft by tightening the attaching screws.
^ Tighten the J 34686 attaching screws to 3 - 7 Nm (27 - 62 inch lbs.).
f. Tighten the T handle of the J 34686. This will push the crankshaft rear oil seal into position. Be sure that the J 34686 collar is flush against the engine block.
g. Loosen the T handle completely.
h. Remove the J 34686 attaching screws.
i. Remove the J 34686 tool from the engine block.
j. Make sure that the crankshaft rear oil seal is seated squarely in the bore.





4. Piston, Connecting Rod, and Bearing Installation:
Tools Required: J 8037 Piston Ring Compressor, or equivalent.
a. Install the connecting rod bearings. Use the proper size bearings.
1. Install the bearing inserts into the connecting rod and the connecting rod cap.
2. Lubricate the connecting rod bearings with engine oil.
b. Install the piston and the connecting rod to the correct bore.
1. Slide a piece of 3/8" fuel or vacuum hose over the connecting rod bolts. This protects the crankshaft journal during piston and connecting rod installation.
2. Stagger each piston ring end gap equally around the piston.
3. Lubricate the piston and the piston rings with engine oil.





4. Install J 8037 over the piston. Do not disturb the piston ring end gap location.
5. The piston must be installed so that the mark on the top of the piston faces the front of the engine.
6. Place the piston in its matching bore.
7. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the crankshaft while tapping the piston into place.
8. Hold the J 8037 against the engine block until all the rings have entered the cylinder bore.
9. Remove the vacuum hose from the connecting rod bolts.





c. Install the connecting rod cap.
d. Install the connecting rod bolt nuts.
1. Tighten the connecting rod bolt nuts to 52 Nm (38 ft. lbs.).
2. Loosen the connecting rod bolt nuts 1 full turn.
3. Tighten the connecting rod bolt nuts to 52 Nm (38 ft. lbs.).





e. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.10 - 0.38 mm (0.0039 - 0.0149 inch).

5. Camshaft Installation:

NOTE: If you install a new camshaft, replace all of the valve lifters.





a. Install the camshaft.
b. Coat the camshaft lobes and journals with engine assembly lubricant or equivalent.
c. Handle the camshaft carefully in order to prevent damage to the camshaft bearings.





d. Install the thrust plate bolts.
^ Tighten the thrust plate bolts to 12 Nm (106 inch lbs.).
e. Install the Camshaft Position Sensor.
^ Tighten Camshaft Position Sensor bolt to 10 Nm (89 inch lbs.).
f. Install the camshaft sprocket. Refer to Timing Chain and Tensioner Installation.

6. Timing Chain and Sprockets Installation:
Tool Required: J 5590 Crankshaft Gear Installer, or equivalent.





a. Install the crankshaft sprocket using J 5590. Make sure that the crankshaft sprocket is seated against the crankshaft.
b. Install the timing chain and install the timing chain tensioner.
c. Compress the timing chain tensioner spring.





d. Insert a cotter pin or a nail into the hole in the tensioner to retain the timing chain tensioner shoe.





e. Install the timing chain tensioner. Do not tighten the timing chain tensioner bolts.





f. Align the crankshaft timing marks with the tab on the timing chain tensioner.
g. Align the camshaft timing mark with the tab on the timing chain tensioner.
h. Install the camshaft sprocket and install the timing chain.
^ Tighten the timing chain tensioner bolts to 24 Nm (18 ft. lbs.).
^ Tighten the camshaft sprocket bolt to 130 Nm (96 ft. lbs.).
i. Remove the cotter pin or nail from the hole in the timing chain tensioner.

7. Engine Front Cover and Oil Seal Installation:
Tool Required: J 35468 Seal Centering Tool, or equivalent.

NOTE: The correct tool must be used in order to align the engine front cover. This will ensure that the engine front cover seal will be centered around the crankshaft. The seal must be centered around the crankshaft in order to prevent damage during hub installation.





a. Install the crankshaft front oil seal.
1. Lubricate the seal lips with the engine oil.
2. Use the J 35468 in order to install the seal to the cover.





b. Apply a 10 mm (3/8 inch) wide, by 5 mm (3/16 inch) thick, bead of RTV to the oil pan. Apply the RTV where the oil pan and the engine front cover meet.
c. Apply a 6 mm (1/4 inch) wide, by 3 mm (1/8 inch) thick, bead of RTV to the engine front cover. Apply the RTV where the engine front cover and the engine block meet.





d. Install the engine front cover to the engine block. The J 35468 tool should still be in place.
e. Install the engine front cover bolts.
^ Tighten the engine front cover bolts to 11 Nm (97 inch lbs.).
f. Remove the J 35468 from the engine front cover.





8. Oil Pump Drive Installation Procedure:
a. Install the oil pump drive. Do this by twisting the oil pump drive into place.
b. Install the oil pump drive bolt.
^ Tighten the oil pump drive bolt to 25 Nm (18 ft. lbs.).





9. Oil Pump Installation Procedure:
a. Heat the oil pump drive shaft retainer in hot water.
b. Install the oil pump drive shaft retainer on the oil pump drive shaft.





c. Install the oil pump drive shaft into the oil pump.

CAUTION: Do not crack the oil pump drive shaft retainer when installing the oil pump drive shaft.





d. Install the oil pump.





e. Install the bolt that attaches the oil pump to the rear main bearing cap. Tighten the bolt that attaches the oil pump to the rear main bearing cap to 43 Nm (32 ft. lbs.).





10. Oil Pan Installation:
a. Apply a 2 mm (1/8 inch) diameter bead of RTV sealer or equivalent to the oil pan side sealing flanges.





b. Apply RTV sealer or equivalent to the oil pan surface that contacts the engine front cover.





c. Install a new oil pan rear seal. Apply a small amount of RTV sealer or equivalent to the oil pan rear seal ears.





d. Install the oil pan.





e. Install the oil pan nuts.
^ Tighten the oil pan nuts to 10 Nm (89 inch lbs.).





f. Install the oil pan bolts.
^ Tighten the oil pan bolts to 10 Nm (89 inch lbs.).

11. Oil Filter Adapter and Valve Assembly Installation:
a. Install oil filter bypass valve.
^ Insert a new oil filter bypass valve in the cylinder block.
^ Use a center punch to stake the valve in three places.
b. Install the oil filter adapter.
^ Tighten the oil filter adapter to 35 Nm (26 ft. lbs.).
c. Install a new oil filter.
^ Lubricate the oil filter seal with clean engine oil before installation.
^ Tighten the oil filter 3/4 to one full turn after the gasket contacts the cylinder block.

CAUTION: If the valve lifters and anti-rotation brackets are not installed properly, the valve lifters, the anti-rotation brackets, and the engine could be damaged.

NOTE: When installing new valve lifters, coat the lifters with camshaft assembly lubricant or equivalent.





12. Valve Lifter Installation:
a. Install the valve lifters in the lifter bores.
^ Align the flat sides (top) of the lifters with the flat sides of the anti-rotation brackets.
^ When properly aligned, the flat side of each lifter is aligned parallel to the anti-rotation bracket.
^ The roller at the bottom of each lifter is aligned parallel to the camshaft lobe.





b. Install the anti-rotation brackets on the valve lifters.





c. Install the screws that retain the anti-rotation brackets.
^ Tighten the anti-rotation bracket screws to 11 Nm (97 inch lbs.).