Engine Assembly
Clean all parts before installation. Apply new engine oil to all sliding and rotating parts. Replace bearings if they are peeling, burned or otherwise damaged. Do not reuse gaskets or oil seals.
CONNECTING ROD
1. Measure each connecting rod bolt length, which should be 2.64 inch (67 mm). If length exceeds 2.66 inch (67.5 mm), replace bolt.
Fig. 10 Assembling piston & connecting rod:
2. Assemble piston and connecting rod with exhaust side of piston (single valve recess side) aligned with cap mating mark on connecting rod, Fig. 10.
Fig. 11 Installing piston pin:
3. Using suitable tools, press piston pin into piston, Fig. 11. If installation force is less than 1100 lbs. or greater than 3300 lbs., replace piston pin or connecting rod.
PISTON RINGS
1. Install three piece oil rings on pistons as follows:
a. Apply engine oil to oil ring spacer and rails.
b. Install oil ring spacer so that opening faces upward.
c. Install upper and lower rails. Upper and lower rail are identical and can be installed with either face upward.
Fig. 12 Installing three piece oil rings:
2. Check that both rails are expanded by the spacer tangs, Fig. 12, by checking that both rails turn smoothly in both directions.
3. Install second ring to piston first, then install top ring. Rings must be installed with R marks facing upward.
4. Apply a liberal amount of clean engine oil to second and top piston rings.
Fig. 13 Positioning ring end gap:
5. Position opening of each ring as shown, Fig. 13.
OIL BAFFLE PLATE
Apply suitable locking compound to baffle plate screws, then install baffle plate on cylinder block, torquing screws to 69-95 inch lbs.
CRANKSHAFT
1. Before installing crankshaft, inspect main bearing oil clearance as follows:
a. Remove any foreign material and oil from journals and bearings.
b. Install upper main bearings and thrust bearings. Main bearings with oil grooves are installed into cylinder block and oil groove of the thrust bearing faces the crankshaft.
c. Set crankshaft into cylinder block and position Plastigage on top of journals in axial direction.
d. Install main bearing caps along with lower main bearings according to cap numbers and arrows.
Fig. 14 Main bearing cap tightening sequence:
e. Tighten caps in two or three steps in proper sequence, Fig. 14. Torque to 14 ft.lbs. and tighten additional 90°, then an additional 45°. Do not rotate crankshaft when measuring oil clearances.
f. Remove main bearing caps and measure Plastigage at each journal at widest point for smallest clearance, and at the narrowest point for the largest clearance.
g. If oil clearance exceeds .0031 inch (.08 mm), grind crankshaft and use undersize main bearings.
2. Apply a liberal amount of engine oil to main bearings, thrust bearings and main journals.
3. Install crankshaft and main bearing caps according to cap number and arrow.
4. Tighten main bearing caps, noting the following:
a. Measure bolt length, which should be 3.35 inch (85 mm). If length exceeds 3.37 inch (85.5 mm), replace bolt.
b. Apply engine oil to threads and the seat face of the bolt.
c. Torque bolts in sequence, Fig. 14, to 14 ft.lbs.
d. Place paint mark on each bolt head.
e. Using paint mark as reference, tighten bolts, in sequence, an additional 90°.
f. Tighten bolts, in sequence, an additional 45°.
5. Inspect crankshaft endplay, which should be .0031-.0111 inch (.08-.282 mm).
6. If endplay exceeds .012 inch (.3 mm), grind crankshaft and install oversize thrust bearing or replace crankshaft and thrust bearing. oversize thrust bearings are available in widths of .0837-.0856 inch (2.125-2.175 mm) and .0886-.0906 inch (2.25-2.3 mm).
PISTON & CONNECTING ROD ASSEMBLY
1. Apply a liberal amount of clean engine oil to cylinder walls, pistons and piston rings.
2. Check piston rings for end gap alignment.
3. Using suitable tool, install each piston assembly into cylinder block with L mark (left bank) and R mark (right bank) facing front of engine. Pistons of both banks are the same.
CONNECTING ROD CAP
1. Check connecting rod bearing oil clearances using same procedure as for the main bearing oil clearance. Be sure to align mating marks on cap and connecting rod when installing connecting rod cap. Torque to 22 ft.lbs., then tighten additional 90°.
2. If oil clearance exceeds .004 inch (.1 mm), grind crankshaft and use undersize bearings.
3. Check each connecting rod side clearance, without cap installed. If clearance exceeds .016 inch (.4 mm), replace connecting rod.
4. Apply a liberal amount of engine oil to crankpin journal and connecting rod bearing.
5. Install connecting rod cap with alignment marks aligned.
6. Apply engine oil to threads of connecting rod cap bolts and the seat faces of the nuts.
7. Torque nuts to 22 ft.lbs.
8. Place a paint mark on each nut head.
9. Using paint mark as reference, tighten nuts an additional 90°.
REAR COVER
1. Apply engine oil to rear cover, oil seal and oil seal lip.
2. Press oil seal into rear cover.
3. Install rear cover with new gasket, torquing to 61-95 inch lbs.
4. Cut away portion of gasket that projects out from rear cover assembly toward oil pan side. Do not scratch rear cover assembly.
FRONT COVER
1. Apply engine oil to front cover and a new oil seal.
2. Press oil seal into front cover.
3. Apply engine oil to oil seal lip.
4. Install front cover and new gasket, torquing to 14-19 ft.lbs.
5. Cut away portion of gasket that projects out from front cover assembly toward oil pan side. Do not scratch front cover assembly.
OIL STRAINER, OIL PUMP, OIL PAN & END PLATE
1. Apply engine oil to new O-ring and install oil strainer on oil pump body, torquing to 69-95 inch lbs.
2. Apply engine oil to new O-ring and install oil pump, torquing to 69-95 inch lbs.
3. Apply engine oil to oil pump driveshaft and install oil pump drive shaft in cylinder block.
4. Remove any dirt or oil from oil pan contact surface.
5. If no oil pan gasket is used, apply a continuous bead of suitable sealant to oil pan along the inside of the bolt holes with the ends overlapping.
Fig. 15 Installing oil pan:
6. If an oil pan gasket is used, apply suitable sealant to shaded areas, Fig. 15.
7. Install oil pan, torquing to 69-95 inch lbs.
8. Install end plate, torquing to 69-95 inch lbs.
FLYWHEEL OR DRIVE PLATE, & CLUTCH DISC & CLUTCH COVER
1. Remove any old sealant from bolts and bolt holes. If old sealant cannot be removed from bolt, replace bolt.
2. Apply suitable sealant to bolt threads.
3. On models with manual transmission, install flywheel, torquing bolts, with suitable tool, to 76-81 ft.lbs.
4. On models with automatic transmission, install and tighten drive plate adapter, drive plate and backing plate. Using suitable tool, torque bolts to 76-81 ft.lbs.
5. Using suitable tools, install clutch disc and clutch cover on manual transmission models, torquing to 13-20 ft.lbs.
TIMING BELT PULLEY
1. Reverse direction of tool, then install timing belt pulley and key on crankshaft.
2. Install crankshaft pulley boss.
3. Apply suitable locking compound to threads of pulley lock bolt, then torque bolt to 116-123 ft.lbs. If using new lock bolt, locking compound is not needed.
WATER PUMP & THERMOSTAT ASSEMBLY
1. Remove all dirt, grease and other material from water pump mounting surface.
2. Install water pump with new gasket, torquing to 14-19 ft.lbs.
3. Install thermostat assembly with new gasket, torquing to 14-19 ft.lbs.
VALVE SEAL, VALVE & VALVE SPRING
1. Apply engine oil to inside of new valve seal.
2. Using suitable tools, install valve seals onto valve guides.
3. Install lower spring seats, valves, inner and outer valve springs and the upper seats. Install outer springs with closer pitches toward cylinder head.
4. Using suitable tool, compress valve springs and install retainers.
5. Tap end of valve stem lightly two or three times with a plastic hammer to seat properly.
CYLINDER HEAD
1. Check projection of oil control plugs from cylinder head, which should be .209-.224 inch (5.3-5.7 mm).
2. Apply engine oil to new O-rings and install oil control plugs.
3. Thoroughly remove all dirt, oil or other material from top of cylinder block.
4. Place new cylinder head gasket on left bank with L mark facing upward.
5. Place a new cylinder head gasket on right bank with R mark facing upward.
6. Install cylinder head to cylinder block.
Fig. 16 Cylinder head bolt tightening sequence:
7. Tighten cylinder head bolts as follows:
a. Measure each bolt length. If length of intake bolts exceeds 4.29 inch (109 mm) or length of exhaust bolts exceeds 5.47 inch (139 mm), replace them.
b. Apply engine oil to threads and seat faces of bolts.
c. Torque bolts in sequence, Fig. 16, to 14 ft.lbs.
d. Place paint mark on each bolt head.
e. Using paint mark as reference, tighten bolts, in sequence, an additional 90°.
f. Using paint mark as reference, retighten each bolt, in sequence, an additional 90°.
DISTRIBUTOR & OIL PUMP DRIVE GEAR
1. Remove all old sealant from drive gear.
2. Apply sealant to top surface of drive gear and seat drive gear fully on left camshaft.
CAMSHAFT & CAMSHAFT OIL SEAL
1. Apply a liberal amount of engine oil to journals, lobes and bearings.
2. Place camshaft into cylinder head, then install thrust plate, torquing to 69-95 inch lbs.
3. Apply engine oil to camshaft oil seal lip.
4. Using suitable tools, press oil seals into each cylinder head.
HYDRAULIC LASH ADJUSTERS
1. Pour engine oil into oil reservoir in rocker arm.
2. Apply engine oil to new hydraulic lash adjusters.
3. Carefully install hydraulic lash adjusters into rocker arm. Be careful not to damage O-rings when installing hydraulic lash adjusters.
ROCKER ARM & SHAFT ASSEMBLY & SEAL PLATE
1. Apply engine oil to rocker arm shafts and rocker arm bearing surface.
Fig. 17 Exploded view of rocker arm & shaft assembly:
2. Assemble rocker arm and shaft assembly as shown, Fig. 17. The intake side shaft has twice as many oil holes as the exhaust side shaft.
3. Install rocker arm and shaft assembly.
Fig. 18 Rocker arm bolt tightening sequence:
4. Torque bolts in two or thee steps in sequence, Fig. 18, to 14-19 ft.lbs. Be careful that rocker arm shaft spring does not get caught between shaft and mounting boss during installation.
5. Install seal plates on cylinder head, torquing to 69-95 inch lbs.
CAMSHAFT PULLEYS
1. Place camshaft keys at 12 o'clock position.
2. Install camshaft pulleys with L mark (left bank) and R mark (right bank) at 12 o'clock position.
3. Using suitable tools, torque camshaft bolts to 52-59 ft.lbs.
PCV VALVE & BLIND COVER & VACUUM PIPE
1. Install PCV valve and blind cover, torquing to 69-95 ft.lbs.
2. On models equipped with automatic transmission, install vacuum pipe, torquing to 69-95 ft.lbs.
OIL PUMP DRIVE GEAR
1. Apply a liberal amount of engine oil to circumference of oil pump drive gear hole.
2. Install oil pump drive gear and thrust washer.
3. Apply engine oil to drive gear.
4. Apply engine oil to new O-ring and install O-ring on drive gear cover.
5. Install gear cover to cylinder head, torquing to 69-95 inch lbs.
DISTRIBUTOR SPACER & CYLINDER HEAD COVER
1. Apply engine oil to new O-ring, then install spacer together with O-ring, torquing to 69-95 inch lbs.
2. Place gasket in position on cylinder head cover assembly.
3. Install cylinder head cover along with new seal washers, torquing to 30-39 inch lbs.
TIMING BELT AUTO TENSIONER
1. Set a plane washer at bottom of tensioner body to prevent damage to body plug.
2. Using suitable tool, slowly press in tensioner rod. Do not use a force of more than 3300 lbs.
Fig. 19 Securing tensioner rod in body:
3. Insert a pin to hold tensioner rod in body, Fig. 19.
4. Install auto tensioner on cylinder block, torquing to 14-19 ft.lbs.
5. Install tensioner puller, torquing to 17-22 ft.lbs.
TIMING BELT
1. Install lower pulley, torquing to 27-38 ft.lbs.
Fig. 20 Aligning timing marks:
2. Ensure timing marks are aligned, Fig. 20.
Fig. 21 Installing timing belt:
3. With upper idler pulley removed, hang timing belt on each pulley in order shown Fig. 21. If timing belt is being reused, it must be installed to rotate in original direction. Ensure there is no oil, grease or dirt on timing belt.
4. Install upper idler pulley, torquing to 27-38 ft.lbs.
5. Turn crankshaft two full rotations in direction of rotation and check alignment of timing marks. If timing marks are not aligned, repeat steps two through five.
6. Remove pin from auto tensioner.
7. Turn crankshaft two full rotations in direction of rotation and ensure timing marks are aligned.
Fig. 22 Checking timing belt deflection:
Fig. 23 Intake manifold tightening sequence:
8. Check timing belt deflection, Fig. 22. If deflection is not .2-.28 inch (5-7 mm) with 22 lbs. of force, repeat adjustment starting with step 4. Be sure not to apply tension other than that of auto tensioner.
FINAL ASSEMBLY
1. Install timing belt covers with new gaskets. Torque 6 mm bolts to 69-95 inch lbs. and the 10 mm bolts to 27-38 ft.lbs.
2. Install crankshaft pulley and baffle plate, torquing to 87-130 inch lbs.
3. Install oil filter body, torquing to 14-19 ft.lbs.
4. Apply engine oil to gasket of new oil filter, then install filter, hand tightening only.
5. Place new exhaust manifold gasket in position and install exhaust manifold assembly, tightening nuts and bolts in two or three steps, torquing to 16-21 ft.lbs.
6. Install exhaust manifold insulator, torquing to 14-19 ft.lbs.
7. Connect injector harness, then place new intake manifold gasket in position.
8. Install intake manifold assembly, torquing flange nuts in two or three steps in sequence, Fig. 23, to 14-19 ft.lbs.
9. Apply engine oil to new extension manifold O-ring, then install extension manifold with new gasket, torquing to 14-19 ft.lbs.
10. Install EGR pipe, torquing bolts to 69-95 inch lbs. and the nut to 25-33 ft.lbs.
11. Install distributor as follows:
a. Apply engine oil to O-ring and position O-ring on distributor.
Fig. 24 Aligning distributor mating marks:
b. Apply engine oil to drive gear and align mating marks, Fig. 24.
c. Install distributor into cylinder head with marks facing straight up.
d. Loosely tighten distributor hold-down bolt.
12. Install water inlet pipe, torquing to 32-43 ft.lbs.
13. Install water bypass hose.
14. Install front and rear engine hangers, torquing to 27-38 ft.lbs.
15. Install gusset plates, torquing to 27-38 ft.lbs.
16. Install A/C bracket and idler pulley, torquing bracket bolts to 27-38 ft.lbs. and the idler pulley bolt to 14-19 ft.lbs.
17. Install power steering bracket and idler pulley, torquing to 27-38 ft.lbs.
18. Install engine mounts, torquing to 29-42 ft.lbs.