Part 2

54. Remove the cylinder heads.





55. Remove and discard the gaskets.





56. Remove the valve tappets.

NOTE: The tappets must be marked to ensure installation in their original location.





57. Remove the halt





58. Remove the oil filter adapter.





59. Inspect the o-rings. Replace as necessary.
60. Remove the bolts.





61. Remove the timing chain tensioner.





62. Remove the bolt.





63. Remove the camshaft sprocket and the crankshaft sprocket with the timing chain.





64. Remove the timing chain Guide and the bolts.





65. Remove the bolts and the camshaft thrust plate.





66. Remove the camshaft.





67. Using the camshaft bearing set T65L-6250-A or equivalent, remove the camshaft bearings.





68. Remove the bolts and the oil pump.





69. Remove the oil pump shaft.





70. Remove the nuts and the oil baffle assembly.





71. Remove the nuts (12).

NOTE: Mark the connecting rod caps so they can be installed in their original position.





72. Remove the connecting rod cars.





73. Remove the connecting rod bearings.





74. Remove the five bolts and the three studs.





75. Remove the four crankshaft main bearing caps.





76. Remove the crankshaft. rear oil seal.





77. Remove the crankshaft.





78. Remove the crankshaft main bearings and the crankshaft thrust main bearing.





79. Remove the piston connecting rod assembly.

CAUTION: Place a rubber hose over the connecting rod studs to protect the crankshaft journals and cylinder walls from being damaged.

Assembly Note

NOTE: Before engine assembly use metal cleaner and a suitable plastic or wooden scraper to clean sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.





1. Use SAE 50 engine oil. Install the crankshaft main bearings and the crankshaft thrust main bearing.

NOTE: All crankshaft components must be lubricated before installation.





2. Inspect bearing clearance; refer to Crankshaft Inspection.
Testing and Inspection

NOTE: The crankshaft main bearings are precise selective fit.





3. Apply silicone rubber in two places.





4. Install the crankshaft rear main oil seal.
1) Lubricate the sealing surfaces of the crankshaft rear oil seal with clean engine oil.





2) Install the seal using SST 49 UN01 136.





5. Install the four crankshaft main bearing caps.





6. Install the piston connecting rod assembly using a suitable piston ring compressor.

NOTE:
^ Cylinder walls and piston must be lubricated. Use SAE 50 engine oil.
^ Position with the notch in the piston head toward the front of the engine.

Crankshaft Bearing Caps:

7. Tighten the five bolts and the three studs in pairs in two steps:
1) Tighten to 35 Nm (25 ft. lbs.).
2) Tighten an additional 57 degrees.





8. Install the connecting rod bearings.





9. Install the connecting rod caps.
- For connecting rod component tests refer to Connecting Rod Inspection.
Testing and Inspection

Connecting Rod Nuts:

10. Install the nuts (12).
1) Tighten the nuts in pairs.

Oil Baffle:

11. Install the oil baffle assembly and install the nuts.





12. Install the oil pump shaft.

Oil Pump Bolts:

13. Install the oil pump and the bolts.





14. If removed, use the camshaft bearing installer and install the camshaft bearings.

NOTE: All camshaft components must be lubricated before installation; use SAE 50 engine oil.





15. Install the camshaft.





16. Install the camshaft thrust plate and the bolts.





17. Install the timing chain guide and the bolts.





18. Install the camshaft sprocket and the crankshaft sprocket with the timing chain.





19. Verify the timing mark alignment.

Camshaft Bolt:

20. Install the bolt.

Timing Tensioner:

21. Install the timing chain tensioner.

Oil Filter Adapter:

22. Install the oil filter adapter.





23. Install the valve tappets.

NOTE: Lubricate tappets and bore with SAE 50 engine oil.





24. Install new gaskets.





25. Install the cylinder heads.

Head Torque Sequence:

26. Install bolts and tighten in sequence shown in three steps:
1) Tighten to 30 - 35 Nm (23 - 25 ft. lbs.).
2) Tighten to 70 - 75 Nm (52 - 72 ft. lbs.).
3) Tighten an additional 90 degrees.





27. Install the push rods.

Rocker Shaft:

28. Install the rocker arm shaft assembly and tighten in two steps.
1) Tighten to 30 - 34 Nm (23 - 25 ft. lbs.).
2) Tighten an additional 90 degrees.
29. Install the camshaft synchronizer.