Part 1
SERVICE PRIOR TO ASSEMBLYThe importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.
Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.
ENGINE BLOCK PLUG INSTALLATION
1. Install the engine block coolant drain plug.
2. Apply gasket paste or equivalent to the plug before installation
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
Coolant Jacket Plug to 15 Nm (11 ft. lbs.).
3. Install the cooling jacket core plugs.
4. Apply gasket paste or equivalent to the plugs before installation.
5. Drive the plugs into the block until they are flush using a drift that closely matches the inside diameter of the plus.
6. Install the front oil passage plug and the engine front cover alignment dowels.
IMPORTANT: The front oil passage plug is a special type with a lubrication hole for the timing chain.
7. Do not install any other type of plug in this oil passage.
8. Install the upper oil passage plug
9. Apply gasket paste or equivalent to the plug before installation.
Tighten
Oil Passage Plug to 21 Nm (15 ft. lbs.).
10. Install the right side oil passage plug.
11. Apply gasket paste or equivalent to the plug before installation.
Tighten
Oil Passage Plug to 21 Nm (15 ft. lbs.).
12. Install the rear oil passage plugs.
13. Apply gasket paste or equivalent to the plugs before installation.
Tighten
Tighten The Large Oil Passage Plug to 33 Nm (24 ft. lbs.).
Tighten
Tighten The Small Oil Passage Plug to 15 Nm (11 ft. lbs.).
14. Install the camshaft rear cover and gasket.
Tighten
Tighten camshaft rear cover bolts to 12 Nm (106 inch lbs.).
CRANKSHAFT AND BEARINGS INSTALLATION
1. Apply engine oil to the crankshaft bearing inserts.
2. Install the upper crankshaft bearing inserts.
IMPORTANT: The number 3 crankshaft bearing insert is specific to the number three crankshaft journal.
3. The number 3 crankshaft bearing insert does not have a groove.
4. Install the crankshaft.
5. Install the lower crankshaft bearing inserts to the crankshaft bearing caps.
- Make sure that the inserts are the correct size.
- Measure the crankshaft bearing clearance. Refer to Engine Mechanical Specifications
- Apply engine oil to the inserts.
6. Install the crankshaft bearing caps to the engine block.
7. Install the crankshaft bearing cap bolts to the engine block.
Tighten
Tighten the crankshaft bearing cap bolts first to 50 Nm (37 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
8. Before installing the rear crankshaft bearing cap, coat the face of the block where it mates to the cap with Loctite Flange Sealant 518 or equivalent.
9. Measure the crankshaft end play using the following procedure:
9.1. Firmly thrust the crankshaft rearward.
9.2. Firmly thrust the crankshaft forward.
9.3. This will align the crankshaft bearing and the crankshaft thrust surfaces.
Tighten
Tighten the crankshaft bearing cap bolts to 95 Nm (70 ft. lbs.).
10. Measure the crankshaft end play at the front end of the rear crankshaft 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).
CRANKSHAFT REAR OIL SEAL INSTALLATION
Tools Required
J 34686 Rear Main Bearing Oil Seal Installer
1. Install the crankshaft rear oil seal.
2. Lubricate the seal bore to seal mating surface with engine oil.
3. 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.
4. Align the dowel pin of the tool J 34686 with the dowel pin hole in the crankshaft.
5. Attach tool J 34686 to the crankshaft by tightening the attaching screws.
Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
Tighten the J 34686 attaching screws to 3-7 Nm (27-62 inch lbs.).
6. 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.
7. Loosen the T handle completely.
8. Remove the J 34686 attaching screws.
9. Remove the J 34686 tool from the engine block.
10. Make sure that the crankshaft rear oil seal is seated squarely in the bore.
PISTON, CONNECTING ROD, AND BEARING INSTALLATION
Tools Required
J 8037 Piston Ring Compressor
1. Install the connecting rod bearings. Use the proper size bearings.
1.1. Install the bearing inserts into the connecting rod and the connecting rod cap.
1.2. Lubricate the connecting rod bearings with engine oil.
2. Install the piston and the connecting rod to the correct bore.
2.1. Slide a piece of 9.5 mm (0.375 inch) fuel or vacuum hose over the connecting rod bolts. This protects the crankshaft journal during piston and connecting rod installation.
2.2. Stagger each piston ring end gap equally around the piston.
2.3. Lubricate the piston and the piston rings with engine oil.
2.4. Install J 8037 over the piston. Do not disturb the piston ring end gap location.
2.5. The piston must be installed so that the mark on the top of the piston faces the front of the engine.
2.6. Place the piston in its matching bore.
2.7. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place.
2.8. Hold the J 8037 against the engine block until all the rings have entered the cylinder bore.
2.9. Remove the vacuum hose from the rare belt
IMPORTANT: Ensure that the connecting rod cap is properly oriented on the connecting rod. The tab on the connecting rod should be oriented toward the left (exhaust manifold) side of the engine.
3. Install the connecting rod cap.
4. Install the connecting rod bolt nuts.
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
4.1. Tighten the connecting rod bolt nuts to 52 Nm (38 ft. lbs.).
4.2. Loosen the connecting rod bolt nuts 1 full turn.
4.3. Tighten the connecting rod bolt nuts to 52 Nm (38 ft. lbs.).
5. Measure the connecting rod side clearance with a feeler gauge.
The correct clearance is 0.10-0.38 mm (0.0039-0.0149 inch).
CAMSHAFT INSTALLATION
IMPORTANT: If you install a new camshaft, replace all of the valve lifters.
1. Install the camshaft.
2. Coat the camshaft lobes and journals camshaft assembly lubricant or equivalent.
3. Handle the camshaft carefully in order to prevent damage to the camshaft bearings.
4. Install the thrust plate bolts.
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
Tighten the thrust plate bolts to 12 Nm (106 inch lbs.).
5. Install the camshaft position sensor.
Tighten
Tighten camshaft position sensor bolt to 10 Nm (89 inch lbs.).
TIMING CHAIN AND SPROCKETS INSTALLATION
Tool Required
J 5590 Crankshaft Gear Installer
IMPORTANT: If any of the camshaft drive components are being replaced to correct a noise condition, replace all of the components in the camshaft drive system.
1. Install the crankshaft sprocket using J 5590.
Make sure that the crankshaft sprocket is seated against the crankshaft.
2. Install the timing chain and install the timing chain tensioner.
3. Compress the timing chain tensioner spring.
4. Insert a cotter pin or a nail into the hole in the tensioner to retain the timing chain tensioner shoe.
5. Install the timing chain tensioner. Do not tighten the timing chain tensioner bolts.
6. Align the crankshaft timing marks with the tab on the timing chain tensioner.
7. Align the camshaft timing mark with the tab on the timing chain tensioner.
8. Install the camshaft sprocket and install the timing chain.
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
- Tighten the timing chain tensioner bolts to 24 Nm (18 ft. lbs.).
- Tighten the camshaft sprocket bolt to 130 Nm (96 ft. lbs.).
9. Remove the cotter pin or nail from the hole in the timing chain tensioner.
CRANKSHAFT FRONT COVER OIL SEAL INSTALLATION
Tool Required
J 35468 Seal Centering Tool
NOTICE: 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.
1. Install the crankshaft front oil seal.
1.1. Lubricate the seal lips with the engine oil.
1.2. Use the J 35468 in order to install the seal to the cover.
2. Drive the seal into the cover until it bottoms out in the seal bore.
ENGINE FRONT COVER INSTALLATION
1. Install the engine front cover to the engine block.
2. Ensure that the engine front cover gasket is properly installed in the groove in the engine front cover.
3. Install the engine front cover by hand and engage it fully on the alignment dowel pins.
4. Install the engine front cover bolts.
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
Tighten the engine front cover bolts to 11 Nm (97 inch lbs.).
OIL PUMP INSTALLATION
Oil Pump Drive Installation
1. Install the oil pump drive. Do this by twisting the oil pump drive into place.
2. Install the oil pump drive bolt.
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
Tighten the oil pump drive bolt to 25 Nm (18 ft. lbs.).
Oil Pump Installation
1. Heat the oil pump drive shaft retainer in hot water.
2. Install the oil pump drive shaft retainer on the oil pump drive shaft.
3. Install the oil pump drive shaft into the oil pump.
IMPORTANT: Do not crack the oil pump drive shaft retainer when installing the oil pump drive shaft.
4. Install the oil pump.
5. Install the bolt that attaches the oil pump to the rear main bearing cap.
NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
Tighten the bolt that attaches the oil pump to the rear main bearing cap to 43 Nm (32 ft. lbs.).