Part 2
Oil Pan Installation
1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive to the engine front cover to engine block junction at the oil pan sealing surfaces.
2. Apply a 5mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive to the crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces.
Important:
Always install a New oil pan gasket.
The oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch.
3. Install the New oil pan gasket into the groove in the oil pan.
Important: The oil pan alignment must always be flush or forward no more than 0.3 mm (0.011 in) from the rear face of the engine block.
4. Install the oil pan onto the engine block.
Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing.
5. Slide the oil pan back against a suitable straight edge.
Important: Use a feeler gauge to check the clearance between the oil pan-to-transmission housing measurement points. If the clearance exceeds 0.3 mm (0.011 in) at any of the 3 oil pan-to-transmission housing measurement points (1), then repeat the step until the oil pan-to-transmission housing clearance is within the specification. The oil pan must always be forward of the rear face of the engine block.
6. Install the oil pan bolts and nuts, but do not tighten.
7. Measure the pan-to-transmission housing clearance using a feeler gauge and a straight edge.
Notice: If the clearance is more than 0.3 mm (0.011 in), powertrain durability may be impacted.
8. Tighten the oil pan bolts and nuts in sequence (1-12). Tighten
Tighten the oil pan bolts to 25 N.m (18 lb ft).
9. Measure the clearance between the 3 oil pan-to-transmission housing measurement points in order to ensure proper alignment.
10. Install a NEW oil pan drain plug seal (O-ring) onto the oil pan drain plug.
11. Install the oil pan drain plug into the oil pan. Tighten
Tighten the oil pan drain plug to 25 N.m (18 lb ft).
12. Apply sealant to the threads of the engine oil level sensor (if applicable).
13. Install the engine oil level sensor (if applicable).
Tighten the engine oil level sensor to 20 N.m (15 lb ft).
Crankshaft Balancer Installation
Tools Required
- J 23523-F Balancer Remover and Installer
1. Look to ensure that the front groove pin (crankshaft balancer) is installed in the proper location (if applicable).
Note: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.
2. Apply a small amount of adhesive onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint.
3. Align the keyway of the crankshaft balancer with the crankshaft balancer key.
4. Install the crankshaft balancer onto the end of the crankshaft.
5. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft.
1. Install the J 23523-F into the front of the crankshaft.
2. Rotate the J 23523-F nut until the nut, the washer, and the bearing are firmly against the crankshaft balancer.
3. Use one wrench to hold the J 23523-F forcing screw.
4. Use a second wrench and rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring.
5. Remove the J 23523-F.
6. Install the crankshaft pulley and bolts.
Tighten the crankshaft pulley bolts to 58 N.m (43 lb ft).
7. Install the crankshaft balancer washer and the bolt.
Tighten the crankshaft balancer bolt to 95 N.m (70 lb ft).
Valve Lifter Installation
1. Apply lubricant to the valve lifter rollers.
Important: If reusing the valve lifters, install the valve lifters in the original positions.
2. Install the valve lifters.
3. Install the valve lifter pushrod guides.
Tighten the valve lifter pushrod guide bolts to 16 N.m (12 lb ft).
Cylinder Head Installation (Left)
Tools Required
- J 36660 Electronic Torque Angle Meter
1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the dowel pins (cylinder head locator) for proper installation.
3. Clean the cylinder head gasket surfaces on the cylinder head.
Important: Do not use any type sealer on the cylinder head gasket (unless specified).
4. Install the NEW cylinder head gasket in position over the dowel pins (cylinder head locator).
5. Install the cylinder head onto the engine block.
Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
6. Apply sealant to the threads of the cylinder head bolts~
7. Install the cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in sequence on the first pass.
Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).
9. Use the J 36660 in order to tighten the cylinder head bolts in sequence on the final pass.
- Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees.
- Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees.
- Tighten the short bolts (2, 3, 6, 7,10, and 11) on the final pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts.
Tighten the spark plug wire support bolts to 12 N.m (106 lb in).
11. Measure the NEW spark plug gap if necessary.
Specification
Spark plug gap to 1.52 mm (0.060 in).
12. Install the spark plugs.
- Tighten the spark plug for a USED cylinder head to N.m (11 lb ft).
- Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).
13. Install the engine coolant temperature gauge sensor (if applicable).
Tighten the engine coolant temperature gauge sensor to 20 N.m(1 5 lb ft).
14. Install the engine coolant temperature sensor (if applicable).
Tighten the engine coolant temperature sensor to 20 N.m (1 5 lb ft).
Cylinder Head Installation (Right)
Tools Required
- J 36660 Electronic Torque Angle Meter
1. Clean the cylinder head gasket surfaces on the engine block.
2. Inspect the dowel pins (cylinder head locator) for proper installation.
3. Clean the cylinder head gasket surfaces on the cylinder head.
Important: Do not use any type sealer on the cylinder head gasket (unless specified).
4. Install the NEW cylinder head gasket in position over the dowel pins (cylinder head locator).
5. Install the cylinder head onto the engine block.
Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
6. Apply sealant to the threads of the cylinder head bolts.
7. Install the cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in sequence on the first pass.
Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).
9. Use the J 36660 in order to tighten the cylinder head bolts in sequence on the final pass.
- Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees.
- Tighten the medium bolts (12 and 13) on the final pass in sequence to 65 degrees.
- Tighten the short bolts (2,3,6,7,10, and 11) on the final pass in sequence to 55 degrees.
10. Install the spark plug wire support and bolts.
Tighten the spark plug wire support bolts to 12 N.m (106 lb in).
11. Measure the NEW spark plugs for the proper gap.
Adjust the spark plug gap if necessary.
Specification
Spark plug gap to 1.52 mm (0.060 in).
12. Install the spark plugs.
Tighten the spark plugs for a USED cylinder head to 15 N.m(11 lb ft).
- Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).
Valve Rocker Arm and Push Rod Installation
1. Apply threadlock to the threads of the valve rocker arm ball stud.
Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position.
2. Install the valve rocker arm ball stud.
Tighten the valve rocker arm ball stud to 47 N.m (35 lb ft).
Important: Be sure that the valve pushrods seat in the valve lifter sockets.
3. Install the valve pushrods.
4. Apply prelube to the valve rocker arm and valve rocker arm ball bearing surfaces.
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.
7. Install the valve rocker arm nuts.
8. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57-63 degrees clockwise or counter clockwise from the engine front cover alignment tab (2).
9. Tighten the valve rocker arm nuts.
Tighten valve rocker arm nuts to 25 N.m (18 lb ft).
Intake Manifold Installation
Notice: Applying excessive amounts of sealant may prohibit the intake gasket from sealing properly.
1. Apply a 4.0 mm (0.157 in) patch of adhesive to the cylinder head side of the lower intake manifold gasket at each end.
Important: The lower intake manifold gasket must be installed while the adhesive is still wet to the touch.
2. Install the lower intake manifold gasket onto the cylinder head.
Use the gasket locator pins in order to properly seat the lower intake manifold 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.
Important: The lower in take manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch.
3. Apply a 5 mm (0.197 in) bead of adhesive to the front top of the engine block.
4. Extend the adhesive bead 13 mm (0.50 in) onto the each lower intake manifold gasket.
5. Apply a 5 mm (0.197 in) bead of adhesive to the rear top of the engine block.
6. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
7. Install the lower intake manifold onto the engine block.
8. Apply threadlock to the threads of the lower intake manifold bolts.
9. Install the lower intake manifold bolts.
Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Falling to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.
10. Tighten the lower intake manifold bolts.
1. Tighten the bolts on the first pass in sequence (1 - 8) to 3 N.m (27 lb in).
2. Tighten the bolts on the second pass in sequence (1 - 8) to 12 N.m (106 lb in).
3. Tighten the bolts on the final pass in sequence (1 - 8) to 15 N.m (11 lb ft).
11. Connect the evaporative emission (EVAP) canister solenoid valve harness.
Distributor Installation
Important: The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning number 1 piston at top dead center (TDC). With the piston on the compression stroke and at top dead center, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3).
1. Rotate the crankshaft balancer clockwise until the alignment marks in the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke.
2. Remove the distributor cap bolts and discard.
3. Remove the distributor cap.
4. Align the indent hole on the driven gear with the paint mark on the distributor housing.
5. Ensure that the distributor rotor segment points to the cap hold area.
6. Align the slotted tang in the oil pump drive shaft with the distributor drive shaft. Rotate the oil pump drive shaft with a screwdriver if necessary.
7. Install the distributor and NEW distributor gasket. The flat in the distributor housing must point toward the front of the engine.
8. Once the distributor is fully seated,align the distributor rotor segment with the number 6 pointer (1) that is cast into the distributor base.
9. If the distributor rotor segment does not come within a few degrees of the number 6 pointer (1), the gear mesh between the distributor and camshaft may be off a tooth or more. Repeat the procedure again in order to achieve proper alignment.
10. Install the distributor cap and NEW distributor cap bolts.
Tighten the distributor cap bolts to 2.4 N.m (21 lb in).
11. Install the distributor clamp and bolt.
Tighten the distributor clamp bolt to 25 N.m (18 lb ft).
12. Install the ignition coil wire harness.
Valve Rocker Arm Cover Installation (Left)
Important: Do not reuse the valve cover gasket or the valve rocker arm cover bolt grommets.
1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts.
Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
Valve Rocker Arm Cover Installation (Right)
Important: Do not reuse the valve cover gasket or the valve rocker arm cover bolt grommets.
1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts.
Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
Oil Level Indicator and Tube Installation
1. Apply sealant around the oil level indicator tube 13 mm (0.5 in) below the tube bead.
2. Install the oil level indicator tube into the engine block. Rotate the oil level indicator tube into position.
3. Install the oil level indicator tube bolt.
Tighten the oil level indicator tube bolt to 12 N.m (106 lb in).
4. Install the oil level indicator into the oil level indicator tube.
Water Pump Installation
1. Apply sealant to the threads of the water pump bolts.
2. Install the water pump and the NEW water pump gaskets.
3. Install the water pump bolts.
Tighten the water pump bolts to 45 N.m (33 lb ft).
Important: After final assembly, the water pump inlet hose clamp tangs (water pump end) must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose.
4. Install the water pump inlet hose and the water pump inlet hose clamps.
5. Install the fan and water pump pulley and bolts.
Tighten the fan and water pump pulley bolts to 25 N.m (18 lb ft).
Exhaust Manifold Installation (Left)
1. Install the NEW exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the spark plug wire shields.
4. Apply threadlock to the threads of the exhaust manifold bolts and stud.
5. Install the exhaust manifold bolts and stud.
1. Tighten the exhaust manifold bolts and stud on the first pass to 15 N.m (11 lb ft).
2. Tighten the exhaust manifold bolts and stud on the final pass to 30 N.m (22 lb ft).
6. Install the spark plug wire retainers onto the spark plug wire support.
7. Install the spark plug wires onto the spark plugs
Exhaust Manifold Installation (Right)
1. Install the NEW exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the spark plug heat shields.
4. Apply threadlock to the threads of the exhaust manifold bolts.
5. Install the exhaust manifold bolts.
6. Tighten the exhaust manifold bolts.
1. Tighten the bolts on the first pass to 15 N.m (11 lb ft).
2. Tighten the bolts on the final pass to 30 N.m (22 lb ft).
7. Install the spark plug wire retainers onto the spark plug wire support.
8. Install the spark plug wires onto the spark plugs.
Clutch Pilot Bearing Installation
Caution: Wear safety glasses in order to avoid eye damage.
1. Install the NEW clutch pilot bearing.
2. Measure to ensure the proper installation depth is obtained.
Engine Flywheel Installation
Important: If replacing the engine flywheel (manual transmission), note the position of the original flywheel weights (if applicable). Flywheel weights must be installed into the new engine flywheel in the same location as the old flywheel weights were in the old engine flywheel.
1. Note the position of the flywheel weights and install the NEW flywheel weights as required.
A properly installed flywheel weight will be flush or slightly below flush with the face of the engine flywheel.
2. Install the engine flywheel (1) or (2) to the crankshaft. Align the engine flywheel locator hole to the flywheel locator pin.
3. Install the engine flywheel bolts.
Tighten the engine flywheel bolts in sequence (1-6) to 100 N.m(74 lb ft).
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 normal.
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.