Part 1
Engine
Special Tool(s)
Materials
Assembly
NOTE: During engine assembly it may become necessary to check bearing clearances, end play etc.
1. Read the first character code information on the cylinder block face (1) and record the information.
2. Read the first character on the No. 7 crankshaft counterweight and note it.
3. Using the data recorded in the previous two steps, cross-reference using the chart to obtain bearing grade.
4. NOTE: Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
Lubricate the crankshaft main bearings with clean engine oil and install into the cylinder block. Install the crankshaft main bearings into the main bearing caps.
5. NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
Install the crankshaft onto the upper main bearings.
6. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.
Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.
7. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.
Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
8. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the rear of the engine.
NOTE: To aid in assembly apply petroleum jelly to the back of the crankshaft thrust washer.
Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with the oil grooves facing the crankshaft surface.
9. Install the crankshaft lower main bearings into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or deadblow hammer.
10. NOTE: Crankshaft not shown for clarity.
Install the main bearing cap dowel pins so the flat sides face the crankshaft.
11. NOTE: Crankshaft not shown for clarity.
Install and tighten the new bolts in two stages:
^ Stage l: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
12. NOTE: Crankshaft not shown for clarity.
Install and tighten the new cross-mounted bolts in two stages:
^ Stage 1: Tighten to 30 Nm (22 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
13. NOTE: Verify the connecting rods and rod caps for correct orientation.
NOTE: Carefully tap the connecting rod bolts in. Avoid damaging the connecting rod.
Prepare the connecting rod and caps.
^ Insert the bolts in the rod cap.
^ Insert the upper and lower rod bearings into the rod and cap.
14. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: Make sure the piston arrow is facing forward.
Using the special tools, install the No. 1 and No. 6 piston and connecting rod assemblies.
^ Lubricate the piston and ring with clean engine oil.
^ Lubricate the rod bearings with clean engine oil.
15. Seat the connecting rods on the crankshaft journals and remove the special tools.
16. CAUTION: The rod bearing caps must keep the same orientation as marked during disassembly.
NOTE: The rod bearing cap bolts are torque-to-yield. Install new bolts each time repaired.
Install the rod bearing caps and tighten the bolts in three stages:
^ Stage 1: Tighten to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten to 45 Nm (30 ft. lbs.).
^ Stage 3: Tighten an additional 90 degrees.
17. Install the piston connecting rod assemblies 3 and 5, 4 and 7, 2 and 8, by turning the crankshaft 90 degrees and repeating the previous steps.
18. Position the oil pump and gasket and install the bolts in the sequence shown.
19. Install and tighten the oil pump screen and cover spacer.
20. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.
Install the oil pump screen cover and tube, and the bolts.
21. Install the cylinder head gaskets.
22. Install the LH and the RH cylinder heads. Loosely install the new bolts.
23. Tighten the LH and RH bolts in three stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.
24. Install RH exhaust manifold gaskets and the exhaust manifold.
^ Tighten the nuts in the sequence shown.
25. CAUTION: Timing chain procedures must be followed exactly or damage to the pistons or valves can result.
Compress the tensioner plunger, using the edge of a soft-jawed vise.
26. Install a paper clip into the hose in the tensioner housing to hold the ratchet assembly.
^ Remove the tensioner from the vise.
27. NOTE: There are 61 links in the timing chain.
If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
28. Install the timing chain guides.
29. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is approximately in the 11 o'clock position.
30. NOTE: LH shown, RH similar.
Install the special tools on the LH and RH cylinder heads.
31. Using the special tool, position the crankshaft.
32. Remove the special tool.
33. Install the crankshaft sprocket with the timing mark facing outward.