Part 1

Service Prior to Assembly

- Dirt will cause premature wear of the rebuilt engine. Clean all the components.
- Use the proper tools to measure the components when checking for excessive wear. Components not within the manufacturer's specification must be repaired or replaced.
- When the components are re-installed into an engine, return the components to the original location, position, and direction.
- During assembly, lubricate all the moving parts with clean engine oil (unless otherwise specified). The engine oil will provide the initial lubrication when the engine is first started.

Engine Block Plug Installation

Tools Required
- J 41712 Oil Pressure Switch Socket

Caution: Wear safety glasses in order to avoid eye damage.




1. Install a NEW oil filter bypass valve.
1. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block.
2. Using a pointed punch, stake the engine block area around the oil filter bypass valve.
Stake in 3 locations 120 degrees apart.



2. Apply sealant to the outside diameter of the NEW front engine oil gallery plugs.
3. Install the NEW front engine block oil gallery plugs.
A properly installed front engine oil gallery plug must be installed slightly below flush with the front face of the engine block.




4. Install the spring type S pin (crankshaft rear oil seal housing locator) (if required).




5. Apply sealant to the outside diameter of the NEW expansion cup plug (balance rear bearing hole).
6. Install the NEW expansion cup plug (balance shaft rear bearing hole).




7. Apply sealant to the outside diameter of the NEW expansion cup plug (camshaft rear bearing hole).
8. Install the NEW expansion cup plug (camshaft rear bearing hole).




9. Apply sealant to the threads of the engine block right rear oil gallery plug, the engine block left rear oil gallery plug, and the engine block left side oil gallery plug.
10. Install the engine block right rear oil gallery plug, the engine block left rear oil gallery plug, and the engine block left side oil galley plug.
- Tighten the engine block left side oil gallery plug and the engine block right rear oil gallery plug to 20 N.m (15 lb ft).
- Tighten the engine block left rear oil gallery plug 30 N.m (22 lb ft).




11. Install the dowel straight pins (transmission locator) (if required).




12. Install the left side dowel pins (cylinder head locator) (if required).




13. Install the right side dowel pins (cylinder head locator) (if required).




14. Apply sealant to the threads of the engine block coolant drain hole plug.
15. Install the engine block coolant drain hole plug. Tighten
Tighten the engine block coolant hole plug to 20 N.m (15 lb ft).




16. Apply sealant to the threads of the engine oil pressure sensor fitting.

Important: Do not loosen the engine oil pressure fitting after the initial torque has been obtained.

17. Install the engine oil pressure sensor fitting. Tighten
Tighten the engine oil pressure sensor fitting to 15 N.m (1 1 lb ft).

Important: Do not rotate the engine oil pressure fitting clockwise more than 359 degrees after the initial torque has been obtained.

18. Rotate the engine oil pressure sensor fitting clockwise to the proper position (1), 50 degrees from the centerline (2).




19. Apply sealant to the threads of the engine oil pressure gauge sensor.
20. Install the engine oil pressure gauge sensor using the J 41712.
Tighten the engine oil pressure gauge sensor to 30 N.m(22 lb ft).




21. Apply sealant to the threads of the knock sensor.
22. Install the knock sensor.
Tighten the knock sensor to 20 N.m (15 lb ft).

Oil Filter Adapter Installation




1. Install the NEW oil filter adapter seal (0-ring) into the groove in the oil filter adapter.




2. Install the oil filter adapter and NEW oil filter adapter gasket.




3. Install the oil filter adapter bolts. Tighten
Tighten the oil filter adapter bolts to 21 N.m (15 lb ft).

Crankshaft and Bearings Installation

Tools Required
- J 36660 Electronic Torque Angle Meter




1. Install the crankshaft bearings into the engine block.
2. Apply clean engine oil to the crankshaft bearings.




3. Apply clean engine oil to the crankshaft bearing journals.
4. Install the crankshaft.




5. Install the crankshaft bearings into the crankshaft bearing caps.
6. Apply clean engine oil to the crankshaft bearings.




7. Install the crankshaft bearing caps in the original position and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block.
8. Install the crankshaft bearing cap bolts.
9. Thrust the crankshaft rearward in order to set and align the crankshaft thrust bearings and the crankshaft bearing caps.
10. Thrust the crankshaft forward in order to align the rear faces of the crankshaft thrust bearings.
11. Tighten the crankshaft bearing cap bolts.
1. Tighten the crankshaft bearing cap bolts on the first pass to 20 N.m (15 lb ft).
2. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660.

Crankshaft Rear Oil Seal and Housing Installation

Tools Required
- J 35621-B Rear Main Seal Installer




1. Install the crankshaft rear oil seal housing retainer stud.
Tighten the crankshaft rear oil seal housing retainer stud to 6 N.m (53 lb in).

Important: Always use a NEW crankshaft rear oil seal housing gasket when installing the crankshaft rear oil seal housing.




2. Install the NEW crankshaft rear oil seal housing gasket.




3. Install the crankshaft rear oil housing onto the crankshaft rear oil seal housing retainer stud.
4. Install the crankshaft rear oil seal housing nut and bolts.
Tighten the crankshaft rear oil seal housing nut and bolts to 12 N.m (106 lb in).




5. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing.
6. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange.
7. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin.
8. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface.
9. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal.
Minor imperfections may be removed with a fine grade emery cloth.

Important: DO NOT allow oil or any other lubricants to contact the seal lip surface of the crankshaft rear oil seal.

10. Remove the sleeve from the crankshaft rear oil seal.
11. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal.
12. Install the crankshaft rear oil seal onto the J 35621-B.
13. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug.

Notice: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail.

14. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing.
1. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing.
Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore.
2. Turn the J 35621-B wing nut counter clockwise to release the J 35621-B from the crankshaft rear oil seal.
15. Remove the J 35621-B from the crankshaft.
16. Wipe off any excess engine oil with a clean rag.

Piston, Connecting Rod, and Bearing Installation

Tools Required
- J 5239 Connecting Rod Bolt Guide Set
- J 5037 Ring Compressor
- J 36660 Electronic Torque Angle Meter




1. Apply clean engine oil to the following components:
- The piston
- The piston rings
- The cylinder bore
- The bearing surfaces
2. Install the J 5239 onto the connecting rod bolts.




3. Install the J 8037 onto the piston and compress the piston rings.




4. Install the piston and connecting rod assembly into the proper cylinder.
- The mark on the top of the piston must face the front of the engine block.
- When assembled, the flanges on the connecting rod and connecting rod cap should face to the front of the engine block on the left bank, and to the rear of the engine block on the right bank.
5. Use the J 8037 and the J 5239 and lightly tap the top of the piston with a wooden hammer handle.
- Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore.
- Use the J 5239 in order to guide the connecting rod onto the crankshaft journal.
6. Remove the J 5239.
7. Install the connecting rod cap and nuts.
1. Tighten the nuts evenly on the first pass to 27 N.m (20 lb ft).
2. Use the J 36660 in order to tighten the nuts on the final pass an additional 70 degrees.




8. After the piston and connecting rod assemblies have been installed, then lightly tap each connecting rod assembly (parallel to the crankpin) in order to ensure that the connecting rods have side clearance.
9. Use a feeler gauge or a dial indicator to measure the connecting rod side clearance between the connecting rod caps. The connecting rod side clearance should be 0.15-0.44 mm (0.006-0.017 in).

Camshaft Installation




1. Apply clean engine oil or engine oil supplement to the following components:
- The engine camshaft lobes
- The camshaft bearing journals
- The camshaft bearings
2. Install the three 5/16 - 18 x 4.0 in. bolts into the engine camshaft front bolt holes.

Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings

3. Use the bolts as a handle in order to install the engine camshaft.
4. Remove the three bolts from the front of the engine camshaft.




5. Install the camshaft retainer and bolts.
Tighten the camshaft retainer bolts to 12 N.m (106 lb in).

Balance Shaft Installation

Tools Required
- J 5092 Universal Driver Handle
- J 36660 Electronic Torque Angle Meter
- J 36996 Balance Shaft Installer




1. Apply clean engine oil to the balance shaft front bearing.
2. Use the J 36996 and the J 8092 in order to install the balance shaft.




3. Install the balance shaft retainer and bolts. Tighten
Tighten the bolts to 12 N.m (106 lb in).




4. Apply threadlock to the threads of the balance shaft driven gear bolt.
5. Install the balance shaft driven gear and bolt.
1. Tighten the balance shaft driven gear bolt on the first pass to 20 N.m (15 lb ft).
2. Tighten the balance shaft driven gear bolt on the final pass using the J 36660 an additional 35 degrees.
6. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case.




7. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time.




8. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o'clock position.




9. Remove the balance shaft drive gear.




10. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o'clock position.




11. Position the balance shaft drive gear onto the engine camshaft.
12. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned.

Timing Chain and Sprockets Installation

Tools Required
- J 5590 installer




1. Install the crankshaft balancer key into the crankshaft keyway.
The crankshaft balancer key should be parallel to the crankshaft or with a slight incline.




2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key.

Caution: Wear safety glasses in order to avoid eye damage.

3. Use the J 5590 in order to install the crankshaft sprocket.




4. Rotate the crankshaft until the crankshaft sprocket alignment mark is at the 12 o'clock position.

Important: Install the camshaft sprocket with the alignment mark at the 6 o'clock position.

5. Install the camshaft sprocket and the camshaft timing chain.




6. Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position.

Important: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug (camshaft rear bearing hole).




7. Install camshaft sprocket bolts.
Tighten the camshaft sprocket bolts to 25 N.m (18 lb ft).




8. Install the crankshaft position sensor reluctor ring.
1. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft.
2. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket.

Engine Front Cover Installation

Important: Once the composite engine front cover is removed DO NOT reinstall the engine front cover. Always install a NEW engine front cover.




1. Install the NEW engine front cover.
2. Install the engine front cover bolts.
Tighten the bolts to 12 N.m (106 lb in).




Important: DO NOT reuse the original crankshaft position sensor seal (O-ring). When installing the crankshaft position sensor be sure the crankshaft position sensor is fully seated and held stationary in the engine front cover crankshaft position sensor bore. A crankshaft position sensor that is not completely seated will cock in the engine front cover and may result in erratic engine operation.

3. Lubricate the NEW crankshaft position sensor seal (O-ring) with clean engine oil.
4. Install the NEW crankshaft position sensor seal (O-ring) onto the crankshaft position sensor.




5. Install crankshaft position sensor.
6. Install crankshaft position sensor bolt.
Tighten the crankshaft position sensor bolt to 8 N.m (71 lb in).

Oil Pump Installation




1. Inspect for properly installed pins (oil pump locator).

Important: Do not reuse the oil pump drive shaft retainer. During assembly, install a NEW oil pump drive shaft retainer.




2. Install the oil pump.
3. Position the oil pump onto the pins.




4. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap.
Tighten the oil pump bolt to 90 N.m (66 lb ft).