Part 2
OIL PAN INSTALLATION
IMPORTANT: Apply the proper amount of adhesive 25 mm (1.0 inch) into the areas where the front cover and rear housing meet the engine block oil pan surface.
1. Apply a 5 mm (0.196 inch) bead of adhesive 25 mm (1.0 inch) long to the engine front cover to engine block junction.
2. Apply a 5 mm (0.196 inch) bead of adhesive 25 mm (1.0 inch) long to the crankshaft rear oil seal housing to engine block junction.
IMPORTANT: Always install a new oil pan gasket.
The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch.
3. Install the oil pan gasket.
4. Install the oil pan against to engine block.
IMPORTANT: The oil pan alignment must always be flush or forward of the rear face of the engine block.
5. Slide the oil pan back against a suitable straight edge.
IMPORTANT: Use a feeler gauge to check the clearance between the three oil pan-to-transmission bell housing contact points. If clearance exceeds 0.3 mm (0.011 inch) at any of the three points repeat steps until the clearance is within specification.
NOTICE: Refer to Fastener Notice in Service Precautions.
6. Install oil pan bolts and nuts. Do not tighten.
NOTICE: If the clearance is more than 0.3 mm (0.011 inch), powertrain durability may be impacted.
7. Recheck the oil pan alignment.
Tighten
Tighten the bolts and nuts in sequence (1-12) to 25 Nm (18 ft. lbs.).
8. Again measure the clearance between the three oil pan-to-transmission bell housing contact points to verify proper alignment.
VALVE LIFTER INSTALLATION
1. Coat the valve lifter rollers with prelude.
2. If reusing the valve lifters, install in their original location.
3. Install the valve lifters.
4. Install the valve lifter pushrod guides.
Tighten
Tighten the valve lifter pushrod guide bolts to 16 Nm (12 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
CYLINDER HEAD INSTALLATION
Tools Required
J 36660 Torque Angle Meter
1. Install the new cylinder head gasket.
Install the gasket over the locating pins, with the yellow side of the tab on the outboard side facing up.
2. Install the cylinder head over the locating pins and the gasket.
3. Apply sealant to the threads of the cylinder head bolts.
4. Install the cylinder head bolts finger tight.
Tighten
Tighten the cylinder head bolts on the first pass in sequence (1-13) to 30 Nm (22 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
5. Use the J 36660 in order to tighten the cylinder head bolts on the final pass in sequence (1-13):
Tighten
- Tighten the short bolts (11, 7, 3, 2, 6, 10) 55 degrees.
- Tighten the medium bolts (12,13) 65 degrees.
- Tighten the long bolts (1, 4, 8, 5, 9 ) 75 degrees.
VALVE ROCKER ARM AND PUSH ROD INSTALLATION
1. Apply thread-lock to the threads of the new valve rocker arm ball stud.
IMPORTANT: Be sure to keep parts in order. Parts must be reinstalled into their original location and position.
NOTICE: Refer to Fastener Notice in Service Precautions.
2. Install the valve rocker arm ball stud.
Tighten
Tighten the valve rocker arm ball stud to 47 Nm (35 ft. lbs.).
3. Coat the valve rocker arm and valve rocker arm ball bearing surfaces with prelude.
IMPORTANT: Be sure that the valve pushrods seat in the valve lifter sockets.
4. Install the valve pushrods.
5. Install the valve rocker arms.
6. Install the valve rocker arm balls.
IMPORTANT: Once the valve rocker arm nuts are Installed and properly torqued, no additional valve lash adjustment is required.
NOTICE: Refer to Fastener Notice in Service Precautions.
7. Install the valve rocker arm nuts.
Tighten
Tighten valve rocker arm nuts to 25 Nm (18 ft. lbs.)
INTAKE MANIFOLD INSTALLATION (UPPER)
1. Install a NEW upper intake manifold gasket into the groove of the intake.
IMPORTANT: Two stud type bolts installed into the lower intake manifold diagonally opposite from each other will aid in positioning upper intake manifold to the lower intake manifold.
2. Install the upper intake manifold. Do not pinch the injector wires between the upper and lower intake manifolds.
NOTICE: Refer to Fastener Notice in Service Precautions.
3. Install the upper intake manifold bolts and studs.
4. Tighten the upper intake manifold bolts and studs:
Tighten
4.1. Tighten the upper intake manifold bolts and studs on the first pass to 5 Nm (44 inch lbs.).
4.2. Tighten the upper intake manifold bolts and studs on the final pass to 10 Nm (88 inch lbs.).
5. Install the vacuum hoses.
6. Install ignition coil and studs.
Tighten
Tighten the ignition coil studs to 12 Nm (106 inch lbs.).
INTAKE MANIFOLD INSTALLATION (LOWER)
NOTICE: Applying excessive amounts of sealant may prohibit the intake gasket from sealing properly.
IMPORTANT: Do not reuse intake manifold gaskets. Always install new gaskets.
1. Apply a 4.0 mm (0.157 inch) patch of adhesive to the cylinder head side of the intake manifold gasket at each end.
IMPORTANT: The intake manifold gasket must be installed while the adhesive is still wet to the touch.
2. Install the gaskets onto the cylinder heads.
Use the gasket locator pins in order to properly seat the gasket on the cylinder head.
NOTICE: Care must be used to apply the correct amount of sealant onto the gaskets. Applying excessive amounts of sealant may prohibit the intake gaskets from sealing properly.
3. Apply a 5 mm (0.197 inch) bead of adhesive to the front of the engine block sealant areas. Extend the adhesive bead 13 mm (0.5 inch) up onto each cylinder head in order to seal and retain the gaskets.
4. Apply a 5 mm (0.197 inch) bead of adhesive to the back of the engine block sealant areas. Extend the adhesive bead 13 mm (0.5 inch) up onto each cylinder head in order to seal and retain the gaskets.
5. Install the lower intake manifold to the engine. Apply thread-lock to the lower intake manifold bolts.
NOTICE: Refer to Fastener Notice in Service Precautions.
6. Install the lower intake manifold bolts.
7. Use the tightening sequence shown (1-8) in order to tighten the bolts in three steps.
Tighten
7.1. Tighten the bolts on the first pass to 3 Nm (27 inch lbs.).
7.2. Tighten the bolts on the second pass to 12 Nm (106 inch lbs.).
7.3. Tighten the bolts on the final pass to 15 Nm (11 ft. lbs.).
8. Install the oxygen sensor wire support bracket and nut.
9. Install canister purge system tubing.
THROTTLE BODY INSTALLATION
1. Install a NEW throttle body gasket into the groove of the upper intake manifold.
2. Install the throttle body onto the intake manifold.
NOTICE: Refer to Fastener Notice in Service Precautions.
3. Install the throttle body studs.
Tighten
Tighten the throttle body studs to 9 Nm (80 inch lbs.).
CRANKSHAFT BALANCER INSTALLATION
Tools Required
J 23523-F Crankshaft Balancer Remover and Installer
1. Apply adhesive onto the crankshaft key and into the crankshaft balancer keyway.
NOTICE: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance.
2. Use the following procedure in order to install the crankshaft balancer hub:
2.1. Set the number 1 piston to the top dead center.
2.2. While viewing from the front of the crankshaft, check the reluctor ring and verify that the keyway of the ring is properly orientated with the key of the crankshaft and that the ring is completely seated against the crankshaft sprocket.
3. Install the crankshaft balancer onto the crankshaft.
The crankshaft balancer keyway must align with the crankshaft key.
4. Use the J23523-F in order to install the crankshaft balancer.
4.1. Install the J23523-F into the front of the crankshaft.
4.2. Use a wrench and rotate the tool nut clockwise until the balancer is installed completely onto the crankshaft.
If required, use a second wrench and hold the J23523-F threaded screw.
4.3. Remove the J 23523-F:
NOTICE: Refer to Fastener Notice in Service Precautions.
5. Install the crankshaft pulley and bolts.
Tighten
Tighten the pulley bolts to 58 Nm (43 inch lbs.).
6. Install the crankshaft balancer bolt and washer.
Tighten
Tighten the crankshaft balancer bolt to 100 Nm (74 ft. lbs.).
DISTRIBUTOR INSTALLATION
IMPORTANT: The engine front cover has two alignment tabs and the crankshaft balancer has two alignment marks (spaced 90 degrees apart) which are used for positioning number one piston at top dead center. With piston number one on the compression stroke and at top dead center, the crankshaft balancer alignment marks will align with the engine front cover tabs at the 2 o'clock and 5 o'clock positions.
1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the timing tabs on the engine front cover and number one piston is at top dead center of compression stroke.
2. Loosen the distributor cap screws and remove the distributor cap.
3. Align the indent hole on the driven gear with the white paint mark on the lower distributor shaft housing.
4. Align the slotted tang in the oil pump driveshaft with the distributor driveshaft.
Rotate the oil pump driveshaft with a screwdriver if necessary.
IMPORTANT: If the distributor is difficult to seat, check the alignment of the distributor drive gear with the oil pump driveshaft.
5. Install the distributor.
6. Once the distributor is fully seated, the distributor rotor segment should align with the pointer (6) cast into the distributor base. The distributor housing will have two pointers (6) and (8) cast into the base.
NOTICE: Refer to Fastener Notice in Service Precautions.
7. Install the distributor clamp bolt.
Tighten
Tighten the distributor clamp bolt to 25 Nm (18 ft. lbs.).
IMPORTANT: Do not overtighten the distributor cap screws.
8. Install the distributor cap and screws.
Tighten
Tighten the distributor cap screws to 5 Nm (44 inch lbs.).
VALVE ROCKER ARM COVER INSTALLATION
IMPORTANT: Do not reuse the valve rocker arm cover gasket or bolt grommets.
1. Install a NEW valve rocker arm cover gasket into the groove of the cover.
2. Install NEW bolt grommets into the valve rocker arm cover.
3. Install the cover onto the cylinder head.
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Install the valve rocker arm cover bolts.
Tighten
Tighten the bolts to 12 Nm (106 inch lbs.).
5. Install the PCV valve and pipe.
WATER PUMP INSTALLATION
1. Apply sealant to the threads of the water pump bolts.
2. Position the water pump and gaskets to the engine block.
NOTICE: Refer to Fastener Notice in Service Precautions.
3. Install the water pump bolts.
Tighten
Tighten the water pump bolts to 45 Nm (33 ft. lbs.).
4. Install the coolant bypass hose and clamps.
EXHAUST MANIFOLD INSTALLATION (LEFT SIDE)
1. Install the NEW exhaust manifold gaskets.
2. Install the exhaust manifold.
3. Apply thread-lock to the threads of the exhaust manifold bolts and stud.
NOTICE: Refer to Fastener Notice in Service Precautions.
IMPORTANT: Begin with the center bolts and alternate side-to-side working outward until all the bolts and stud have been tightened.
4. Install the exhaust manifold heat shields, bolts, and stud.
Tighten
4.1. Tighten the exhaust manifold bolts and stud on the first pass to 15 Nm (11 ft. lbs.).
4.2. Tighten the exhaust manifold bolts and stud on the final pass to 30 Nm (22 ft. lbs.).
5. Install the EGR inlet pipe into the intake and exhaust manifolds.
6. Install the EGR clamp bolt to the intake manifold.
Tighten
6.1. Tighten the EGR inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
6.2. Tighten the EGR inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
6.3. Tighten the EGR clamp bolt to 25 Nm (18 ft. lbs.).
EXHAUST MANIFOLD INSTALLATION (RIGHT SIDE)
1. Install the NEW exhaust manifold gaskets.
2. Install the exhaust manifold.
3. Apply thread-lock to the threads of the exhaust manifold bolts.
NOTICE: Refer to Fastener Notice in Service Precautions.
IMPORTANT: Begin with the center bolts and alternate side-to-side working outward until all the bolts have been tightened.
4. Install the exhaust manifold heat shields and bolts.
Tighten
4.1. Tighten the exhaust manifold bolts on the first pass to 15 Nm (11 ft. lbs.).
4.2. Tighten the exhaust manifold bolts on the final pass to 30 Nm (22 ft. lbs.).
ENGINE FLYWHEEL INSTALLATION
IMPORTANT: If replacing the manual transmission flywheel, note the position of the original balance weights (if applicable). Balance weights must be installed into the new flywheel in the same location.
1. Note the position of flywheel balance weights (manual transmission applications), install as required.
A properly installed balance weight will be installed until flush or slightly below flush with the face of the flywheel.
2. Install the engine flywheel (1) or (2) to crankshaft.
3. Align the locator hole to the pin.
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Install the engine flywheel bolts.
Tighten
Tighten the engine flywheel bolts in sequence (1-6) to 100 Nm (74 ft. lbs.).
ENGINE SET-UP AND TESTING
After overhaul, the engine must be tested before it is installed in the vehicle. If a suitable test stand is not available, the following procedure can be used after the engine is installed in the vehicle.
1. Fill the crankcase with the proper quantity and grade of oil.
2. Add engine oil supplement to the engine oil.
3. Fill the cooling system with the proper quantity and grade of coolant.
- Whenever the cooling system is serviced or drained for service procedures, two cooling system sealing pellets must be added to the cooling system.
- Cooling system sealing pellets must be crushed prior to installation. The cooling system sealing pellets must be added to the radiator or the pressurized coolant reservoir.
- Do not place the cooling system sealing pellets into a non-pressurized coolant recovery reservoir. On these systems, the pellets must be added to the radiator.
- The sealant pellets may leave a film on the sides of the pressurized and non-pressurized coolant recovery reservoirs. This film is
4. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
5. Start the engine and listen for unusual noises.
6. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
If necessary, install an oil pressure gauge and measure the engine oil pressure.
7. Run the engine at about 1,000 RPM until the engine has reached normal operating temperature.
8. Listen for improperly adjusted or sticking valves, sticking lifters, or other unusual noises.
9. Inspect for oil and/or coolant leaks while the engine is running.
10. Verify that the distributor is properly positioned.
11. Perform a final inspection for the proper engine oil and coolant levels.