Part 1

Engine



































CAUTION: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and 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.

NOTICE: If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

NOTE: Early build vehicles are equipped with the coolant pump drive pulley on the LH intake camshaft, late build vehicles are equipped with the coolant pump drive pulley on the LH exhaust camshaft.

All vehicles

1. NOTE: This procedure is for selecting bearings using a new crankshaft.





Select the crankshaft main bearings for each crankshaft journal.
1. Read the code on the crankshaft flange.
2. Read the code on the cylinder block rear face.
^ The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for main No. 2.
^ The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2 numbers for main No. 4.





2. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
^ For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.

3. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.





Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.





4. Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the lower cylinder block.





5. Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.





6. Install the crankshaft key.

7. Apply clean engine oil to the crankshaft main and rod bearing journals.





8. Position the crankshaft in the cylinder block.

9. NOTICE: The lower cylinder block must be installed and the bolts tightened within 4 minutes of applying the sealant.

NOTE: Clean and degrease both surfaces using metal surface prep before applying sealant.





Apply gasket and sealant to the cylinder block as shown.

10. NOTICE: Fasteners No. 5 through 8 are studs. Fasteners No. 18 through 22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 1 through 4, 17 are M8 x 1.25 mm x 96 mm (0.05 in x 3.75 in) bolts. Fasteners 9 through 12 are M10 x 1.5 mm x 106.8 mm (0.06 in x 4.20 in) /M8 x 1.25 mm x 21.5 mm (0.05 in x 0.84 in) studs. Fasteners 13 through 16 are M10 x 1.5 mm x 106.5 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position or engine damage can result.





Position the lower cylinder block and install the new bolts and new studs.
^ Tighten the bolts and studs in the sequence shown in 4 stages.
^ Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft).
^ Stage 2: Tighten fasteners 9 through 16 to 40 Nm (30 lb-ft).
^ Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees.
^ Stage 4: Tighten fasteners 17 through 22 to 25 Nm (18 lb-ft).





11. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
^ Position the crankshaft to the rear of the cylinder block.
^ Zero the Dial Indicator Gauge with Holding Fixture.
^ Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
^ Acceptable crankshaft end play is 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.





12. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal.





13. Install the engine-to-transaxle separator plate.





14. Position the flexplate and install the bolts.
^ Tighten to 80 Nm (59 lb-ft).

15. Mount the engine on an engine stand.





16. Using the chart, select the correct piston grade size for the cylinder bores.
^ Measure the cylinder block bore diameter.
^ Mark the outside of the block with the appropriate number(s) to identify bore grade size.
^ Choose the correct piston grade size for the cylinder bore.

17. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.

NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to Disassembly and Assembly of Subassemblies - Piston in this section.

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

NOTE: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.





Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.

18. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.





Install the connecting rod caps and the new bolts.
^ Tighten the bolts in 2 stages.
^ Stage 1: Tighten to 23 Nm (17 lb-ft).
^ Stage 2: Tighten to 43 Nm (32 lb-ft).





19. Install the crankcase cover, a new gasket and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





20. NOTE: LH shown, RH similar.

Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown in 6 stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 3: Loosen one full turn.
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten 90°.
^ Stage 6: Tighten 90°.





21. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).

22. Apply clean engine oil to the LH and RH camshaft roller followers.





23. CAUTION: The camshaft roller followers must be installed in their original positions.

NOTE: RH shown, LH similar.

Install the LH and RH camshaft roller followers.

24. Apply clean engine oil to the LH and RH camshafts.





25. Install the LH and RH camshafts.
^ Locate the camshafts as shown.

Early build vehicles





26. CAUTION: Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.

NOTICE: The camshaft roller followers must be installed in their original positions or damage to the engine may occur.

Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
^ Loosely install the bolts.





27. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
^ Loosely install the bolts.





28. Install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

Late build vehicles





29. CAUTION: Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.

NOTICE: The camshaft caps must be installed in their original positions or damage to the engine may occur.

Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
^ Loosely install the bolts.





30. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
^ Loosely install the bolts.





31. Install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

All vehicles





32. CAUTION: Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.

Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the bearing caps.
^ Loosely install the bolts.





33. Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
^ Loosely install the bolts.





34. Install the bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).





35. NOTE: Clean the sealing surface with metal surface cleaner before installing a new press-in-place gasket.

NOTE: Early build shown, late build similar.

Install the camshaft oil seal retainer and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





36. NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.

NOTE: Early build shown, late build similar.

Using the special tools, Install a new camshaft oil seal.





37. CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.





Install the special tool in the camshaft as shown in the illustration.
^ Adjust the collar on the special tool screw to get the best thread alignment in the rear of the camshaft.

38. NOTICE: On early build engines, the OEM pulley is pressed on 4.74 mm (0.18 in) past flush of the end of the camshaft. On late build engines, the OEM pulley is pressed on flush to the end of the camshaft. Service pulleys on all engines are pressed on flush to the end of the camshaft.

NOTICE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-458).





Position the coolant pump pulley over the previously installed special tool and on the end of the camshaft. Install the special tools as shown in the illustration.
^ Using the special tools, install a new service coolant pump pulley flush with the end of the camshaft.