Part 1
Engine
Special Tool(s)
Material
Engine-Lower Components
Engine-Upper Components
Engine-Front Components
Cylinder Heads
Engine-External Components
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
CAUTION: The moving components must be lubricated with clean engine oil before assembly.
CAUTION: The components with oil holes must be correctly aligned with the oil feed holes.
1. If necessary, install the following:
1. Cylinder block dowels
2. Oil gallery plugs
3. Water jacket plugs
2. Using the Camshaft Service Set, install the engine dynamic balance shaft bearings.
3. Using the Camshaft Service Set, install the camshaft bearings.
4. Install the following:
1. Engine dynamic balance shaft bearing cover
2. Camshaft bearing cover
5. If equipped, install the block heater.
^ Tighten to 2 Nm (18 inch lbs.).
6. CAUTION: Make sure the components are installed in the correct locations.
NOTE: Lubricate the crankshaft main bearings with clean engine oil prior to installation.
Install the crankshaft upper main bearings and the crankshaft upper thrust main bearing.
7. CAUTION: The crankshaft journals must be protected from damage when installing the crankshaft.
Position the crankshaft.
CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance.
8. NOTE: If the rear main bearing cap is not installed within 4 minutes, remove the sealant and reapply.
Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket and sealant to the rear main bearing cap-to-cylinder block parting line.
9. Install the main bearing caps. Tighten the bolts in 2 stages.
^ Stage 1: Tighten to 55 Nm (41 ft. lbs.).
^ Stage 2: Rotate an additional 90 degrees.
10. Using a piston ring compressor, compress the piston rings.
11. CAUTION: Inspect the piston clearance.
CAUTION: Do not damage the cylinder wall with the sharp edges of the connecting rod.
NOTE: 4.2L shown, 3.9L similar.
Install the piston with the arrow on the piston face pointing toward the front of the engine.
12. CAUTION: Inspect the connecting rod bearing clearance.
CAUTION: The connecting rod cap will fit only one way.
Position the lower connecting rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal.
13. Tighten the connecting rod cap bolts in 3 stages.
^ Stage 1: Tighten to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 3: Tighten an additional 105 degrees.
14. Install the remaining pistons and the connecting rods.
15. Install the oil pan baffle and the retaining nuts.
^ Tighten to 32 Nm (24 ft. lbs.).
16. Using a new gasket, install the oil pump screen cover and tube
1. Tighten to 25 Nm (18 ft. lbs.).
2. Tighten to 32 Nm (24 ft. lbs.).
17. CAUTION: Do not damage the camshaft lobes when installing the camshaft.
Install the camshaft, camshaft spacer and camshaft key.
18. Install the camshaft thrust plate and bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
19. Install the engine dynamic balance shaft assembly and bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
20. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and the camshaft keyway will be at 6 o'clock on the camshaft.
Install the engine balance shaft drive gear so that the timing mark lines up with the timing mark on the engine balance shaft driven gear.
21. NOTE: Lubricate the valve tappets with clean engine oil prior to installing. If reusing the valve tappets, make sure to install them in their original locations.
Install the valve tappets.
^ Install the valve tappets.
^ Install the tappet guide plates and retainers.
^ Install the bolts and tighten to 12 Nm (9 ft. lbs.).
22. Install the timing chain tensioner and bolts.
^ Position the timing chain tensioner.
^ Install the bolts and tighten to 11 Nm (8 ft. lbs.).
23. If necessary, compress the tensioner pad and install a retaining pin.
24. Rotate the crankshaft so the number 1 piston is at top dead center (TDC) and the keyway is at the 12 o'clock position.
25. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
26. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
27. CAUTION: All timing marks must be aligned with the No. 1 cylinder set on TDC of the compression stroke or the synchronizer assembly will not be installed correctly.
NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.
Make sure the timing marks and the keyways are aligned.
28. Remove the retaining pin.
29. Install the synchronizer drive gear and the bolt.
^ Tighten to 45 Nm (33 ft. lbs.).
30. NOTE: Use Thread Sealant with Teflon on studs No. 4 and 6 and bolt No. 12.
Install the engine front cover studs in their original locations.
^ Tighten the engine front cover studs to 7 Nm (62 inch lbs.).
31. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
Using a new gasket, install the engine front cover.
^ Using a new gasket, install the coolant pump.
^ Tighten the fasteners in the sequence shown.
Tighten capscrew No. 12 to 10 Nm (89 inch lbs.).
Tighten all other fasteners to 28 Nm (21 ft. lbs.).
32. Clean and inspect the mating surface.
33. NOTE: Lubricate the crankshaft front seal lips with clean engine oil prior to installation.
Assemble the special tools, then place the crankshaft front seal onto the special tools.
34. Using the special tools, install the crankshaft front seal.
35. Apply a bead of Silicone Gasket and Sealant to the keyway in the crankshaft damper. Using the special tool, position and install the crankshaft damper.
36. Install the crankshaft pulley bolt.
^ Tighten to 160 Nm (118 ft. lbs.).
37. CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression stroke on the No. 1 cylinder.
CAUTION: A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.
Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
38. NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.
NOTE: During installation, the arrow on the special tool will rotate clockwise as the gears engage.
Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 54 degrees from the centerline of the engine.
39. Install the camshaft synchronizer retaining bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
40. Install the CMP sensor.
^ Tighten to 3 Nm (27 inch lbs.).
41. NOTE: If the oil pan is not installed within 4 minutes, remove the sealant and reapply.
Clean and apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.
1. Apply silicone gasket and sealant to the rear main bearing cap.
2. Install the oil pan rear seal.
3. Clean the oil pan mating surfaces with metal surface cleaner and apply silicone gasket and sealant to the oil pan mating surfaces.
42. Tighten the oil pan bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
43. Install the oil pressure sensor.
^ Tighten to 27 Nm (20 ft. lbs.).
44. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
If equipped, install the new oil cooler and tube assembly.
45. NOTE: Tighten the oil filter one-half turn after the gasket makes contact with the oil filter housing.
Install a new oil filter.
46. NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.
Using new gaskets, install the RH and the LH cylinder heads.
47. CAUTION: Always use new bolts.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the new bolts. Make sure the bolts are installed in the correct locations.
1. Install the new long bolts.
2. Install the new short bolts.