Part 2

Oil Pan Installation




1. Apply a 2 mm (1/8 in) diameter bead of Loctite 5900© RTV sealer or equivalent to the oil pan side sealing flanges.




2. Apply Loctite 5900© RTV sealer or equivalent to the oil pan surface that contacts the engine front cover.




3. Install a new oil pan rear seal. Apply a small amount of Loctite 5900© RTV sealer or equivalent to the oil pan rear seal ears.




4. Install the oil pan.




5. Install the oil pan nuts.
Tighten the oil pan nuts to 10 N.m (89 lb in).




6. Install the oil pan bolts.
Tighten the oil pan bolts to 10 N.m (59 lb in).

Oil Filter Adapter Installation




1. Install the oil filter bypass valve.
1. Insert the new oil filter bypass valve in the cylinder block
2. Use a center punch to stake the valve in three places.




2. Install the oil adapter.
Tighten the oil filter adapter to 35 N.m (26 lb ft).




3. Install a new oil filter
1. Lubricate the oil filter seal with clean engine oil before installation.
2. Tighten the oil filter 3/4 to one full turn after the gasket contacts the cylinder block.

Valve Lifter Installation

Notice: 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.

Important: When installing new valve lifters, coat the lifters with camshaft assembly lube or equivalent.




1. 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.




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




3. Install the screws that retain the anti-rotation brackets.
Tighten the anti-rotation bracket screws to 11 N.m (97 lb in).

Cylinder Head Installation

Tool Required
- J36660 Torque Angle Meter




1. Install the cylinder head gasket to the block.
2. Use a socket to push cylinder head gasket over the rear dowel pin.

Important: Install the cylinder head gasket over the rear dowel pin.




3. Carefully guide cylinder head into place over the dowel pins. This operation may require an assistant.




4. Install the cylinder head bolts by hand.
5. Install the cylinder head bolts.




6. Use the following sequence in order to tighten the cylinder head bolts:
Tighten the long cylinder head bolts to 63 N.m (46 lb ft).
Tighten the short cylinder head bolts to 58 N.m (43 lb ft).
1. Tighten bolt 1 to 63 N.m (46 lb ft).
2. Tighten bolt 2 to 58 N.m (43 lb ft).
3. Tighten bolt 3 to 58 N.m (43 lb ft).
4. Tighten bolt 4 to 63 N.m (46 lb ft).
5. Tighten bolt 5 to 63 N.m (46 lb ft).
6. Tighten bolt 6 to 58 N.m (43 lb ft).
7. Tighten bolt 7 to 58 N.m (43 lb ft).
8. Tighten bolt 8 to 63 N.m (46 lb ft).
9. Tighten bolt 9 to 63 N.m (46 lb ft).
10. Tighten bolt 10 to 58 N.m (43 lb ft).
11. Use J 36660 to tighten all the cylinder head bolts an additional 90 degrees in sequence.




7. Install the engine lift bracket onto the rear of the engine.
Tighten the engine lift bracket nut to 30 N.m (20 lb ft).

Valve Rocker Arm and Push Rod Installation

Important: When you install new rocker arms, lubricate the pivot bearing and the mating surfaces with Camshaft Assembly Lubricant or equivalent.




1. Install the pushrods.
Ensure that the pushrods seat in the lifters.




2. Install the rocker arms.
3. Ensure that the locating tab on the rocker pivot is properly aligned with the notch in the cylinder head.

Important: Do not over tighten the rocker arm bolts.

Tighten the rocker arm bolts to 25 N.m (19 lb ft).

Valve Rocker Arm Cover Installation




1. Clean the sealing surfaces where the cylinder head and the rocker arm cover meet. Use a suitable cleaning solvent.
2. Inspect the sealing flanges of the rocker arm cover for distortion.
3. Install the new rocker arm cover gasket in the groove around the rocker arm cover.




4. Install the rocker arm cover to the cylinder head.
5. Install the rocker arm cover bolts in sequence.
Tighten the rocker arm cover bolts to 10 N.m (89 lb in).

Intake Manifold Installation




1. Install the intake manifold gasket.
2. Install the intake manifold.




3. Install the intake manifold bolts.
Tighten the bolts in sequence to 24 N.m (17 lb ft).
4. Install the rear EGR port cover to the cylinder head.




5. Install the rear EGR port cover to cylinder head bolts.
Tighten the rear EGR port cover bolts to 11 N.m (97 lb in).




6. Install the throttle body to the intake manifold.
Tighten the throttle body to intake manifold bolts to 10 N.m (89 lb in).

Crankshaft Balancer and Hub Installation

Tool Required
- J 29113 Crankshaft Pulley Hub Installer




1. Coat the front cover seal contact area with engine oil.




2. Apply RTV sealer or equivalent to the keyway in the crankshaft.
3. Install the key into the keyway on the crankshaft.




4. Install the pulley hub into position over the key on the crankshaft.




5. Install the J 29113 through the hub and into the crankshaft so that at least 6 mm (0.24 in) of thread are engaged.
6. Pull the crankshaft pulley hub into position against the J 29113.
7. Remove the J 29113 from the crankshaft.
8. Make sure that the hub is seated against the crankshaft.




9. Position the crankshaft pulley over the crankshaft pulley hub.
10. Install the crankshaft pulley bolts.
Tighten the crankshaft pulley bolts to 50 N.m (37 lb ft).
11. Install the crankshaft pulley to hub bolt.
Tighten the crankshaft pulley to hub bolt to 105 N.m (77 lb ft).

Water Pump Installation




1. Install the water pump gasket to the engine.




2. Install the water pump to the engine.
3. Apply sealant to the bolt threads, use pipe thread sealant or equivalent.




4. Install the water pump attaching bolts.
Tighten the water pump attaching bolts to 25 N.m (18 lb ft.).

Exhaust Manifold Installation




1. Install the exhaust manifold gasket and exhaust manifold.

2. Install the exhaust manifold nuts.
Tighten the exhaust manifold nuts to 13 N.m (118 lb in).

Oil Level Indicator and Tube Installation




1. Install the oil fill tube.

2. Install the oil fill tube.
3. Install the oil fill tube nut.
Tighten the oil fill tube nut to 50 N.m (37 lb ft).
4. Install the oil level indicator.

Engine Flywheel Installation




1. Install the flywheel.
2. Install the flywheel spacer if a flywheel spacer is used.

Important:
You must thoroughly remove the old thread adhesive from the flywheel bolts and bolt holes. Use a round nylon bristle brush in order to remove the old adhesive.
Apply Loctite© 271 or equivalent to all flywheel bolts. Carefully follow the instructions that are included with the thread locking compound in order to ensure that the bolts are retained property.

3. Install the flywheel bolts. Tighten
Tighten the flywheel bolts to 75 N.m (55 lb ft).

Engine Set-Up and Testing

After assembly, test the engine before installing it in the vehicle if possible. If a test stand is not available, use the following procedure.

1. Fill the crankcase with oil.
2. If a new camshaft and lifters have been installed, add engine oil supplement or equivalent to the engine oil.
3. Fill the cooling system with coolant.
4. Add cooling system sealing pellets or equivalent to the engine cooling system.
- Add the pellets directly to the radiator or pressurized coolant reservoir on systems that do not have caps on the radiator.
- Crush the pellets before installation.
5. Crank the engine several times and listen for unusual noises or any other evidence of mechanical problems.
6. Start the engine.
7. Listen for any abnormal engine sounds.
8. Run the engine at 1000 RPM until the engine is at operating temperature.
9. After the engine is at operating temperature, shut the engine off.
10. Inspect the engine carefully for oil or coolant leaks.