Part 1

Engine

Special Tools:

Material:

Upper End - 4.0L SOHC Engine (Part 1):

Upper End - 4.0L SOHC Engine (Part 2):

Lower End - 4.0L SOHC Engine (Part 1):

Lower End - 4.0L SOHC Engine (Part 2):

CAUTION: If used as a leverage device, the fuel rail can be damaged. Care must be taken when working around the fuel rail.

NOTE: During engine assembly it may be necessary to check the bearing clearances and crankshaft end play.

NOTE: Before engine assembly, use silicone gasket remover and metal surface prep and a suitable plastic or wooden scraper to clean the sealing surfaces. Follow the directions on the packaging. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

1. Install the crankshaft main bearings and the thrust bearing.
^ Lubricate the crankshaft main bearings with clean engine oil.

2. Install the lower main bearings in the bearing caps.

3. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance.

Install the crankshaft.

4. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.

5. Install the main bearing caps in the same position from which they were removed.

6. Tighten the bolts.
^ Tighten to 97 Nm (72 ft. lbs.).

7. Check the piston to cylinder bore and ring clearance.

8. NOTE: Lubricate the piston rings with clean engine oil.

Install the piston rings.
9. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.

10. Install the connecting rod bearings.

11. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.

12. NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.

Using the special tool, install the pistons.
^ Rotate the crankshaft as necessary.

13. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.

Check the clearance of each connecting rod bearing.
14. Rotate the crankshaft until the piston is at the bottom of its stroke.

15. NOTE: For cylinders 1, 2 and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5 and 6, remove the opposite nut first.

Loosen the first nut until the face is approximately 2 mm (0.08 inch) over the end of the bolt.

16. Tap on the nut until the bolt can be removed by hand.

17. Repeat the previous 2 steps for the opposite bolt.
18. Install the new bolts, making certain that the bolt head is parallel to the sideward face of the connecting rod.

19. Install the connecting rod cap in the original position.
20. Install and tighten the connecting rod nuts finger-tight.

21. Tighten the connecting rod nuts in 2 stages:
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.

22. Repeat the previous 4 steps for the remaining connecting rods.
23. Rotate the crankshaft until the No. 1 piston is at top dead center (TDC).
24. Install the balance shaft.
1 Install the balance shaft assembly.
2 Install the bolts.
^ Tighten to 29 Nm (21 ft. lbs.).

25. NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete turns of the balance shaft may be required to find the correct position.

Align the timing marks.
^ Install a 4 mm (0.16 inch) pin to hold the shaft in place.

26. Install the balance shaft chain and crankshaft sprocket.

27. Install the balance shaft tensioner and chain guide.
1 Install the balance shaft tensioner.
2 Install the bolts and tighten to 29 Nm (21 ft. lbs.).
3 Position the balance shaft chain guide, install the 2 bolts and tighten to 10 Nm (89 inch lbs.).
^ Remove the pins from the tensioner and the sprocket.
^ Install the crankshaft key.

28. Install the oil pump intermediate shaft, the oil pump and the bolt.
^ Tighten to 19 Nm (14 ft. lbs.).

29. Install the jackshaft.

30. Install the jackshaft thrust plate and bolts.
^ Tighten to 11 Nm (8 ft. lbs.).

31. Install the front cassette and bolt.
^ Tighten to 19 Nm (14 ft. lbs.).

32. Position the jackshaft, the crankshaft sprockets and the chain.

33. Install the chain guide and the bolts.
^ Tighten to 19 Nm (14 ft. lbs.).

34. Install the jackshaft chain tensioner and the bolts.
^ Tighten to 9 Nm (80 inch lbs.).

35. Using the special tool, hold the crankshaft.

36. Install the jackshaft front bolt and tighten in 2 stages.
^ Stage 1: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.

37. Install the oil pump drive and the bolt.
^ Tighten to 19 Nm (14 inch lbs.).

38. Install the RH cassette and sprocket to the jackshaft.
^ Install, but do not tighten the bolt at this time.

39. Install the RH cassette bolt.
^ Tighten to 19 Nm (14 ft. lbs.).

40. Using the special tool, hold the crankshaft.

41. Tighten the rear jackshaft bolt in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.

42. Install the rear jackshaft plug.

43. Position the front cover gasket, the front cover and loosely install the bolts.

44. Install the special tool and tighten the front cover bolts.
^ Tighten to 19 Nm (14 ft. lbs.).

45. NOTE: Lubricate the seal lip with clean engine oil.

Using the special tools, install the crankshaft front oil seal.

46. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the front cover in 4 places.

47. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the rear main bearing cap as shown.
^ Position the cylinder block cradle gasket.

48. CAUTION: The cylinder block cradle inserts must be loosened completely or damage to the cylinder block cradle or oil leaks can result.

Loosen the cylinder block cradle inserts.

49. Position the cylinder block cradle and gasket assembly.

50. Install and finger-tighten the 20 bolts and 2 nuts.

51. Install and finger-tighten the Torx(R) bolts.