Part 1

Engine

Special Tools:

Special Tools:

Special Tools:

Materials:

Material:

Engine - Upper End

Engine- Upper End (Part 1):

Engine- Upper End (Part 2):

Engine- Upper End (Part 3):

Engine - Lower End

Engine-Lower End (Part 1):

Engine-Lower End (Part 2):

Engine-Lower End (Part 3):

1. 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.

Install the crankshaft main bearings.
^ Install the crankshaft upper main bearings into the cylinder block.
^ Install the crankshaft lower main bearings into the bearing caps.
^ Make sure all oil passages are aligned.
^ Lubricate all main bearings with clean engine oil.

2. Lubricate the crankshaft bearing journals with clean engine oil. Install the crankshaft onto the upper crankshaft main bearings.





3. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft thrust surface).

Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.





NOTE: Rotate the jackscrews into the main bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps

4. Install the thrust washer on the rear (No. 5) main bearing cap and install the rear (No. 5) main bearing cap.





5. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
6. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.





7. Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





8. Tighten the jackscrews against the cylinder block in the sequence shown in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).





9. Install the side bolts and tighten them in the sequence shown.
^ Tighten to 21 Nm (15 ft. lbs.).





10. Check the crankshaft end play.
11. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 inch lbs.).
12. Check the piston-to-cylinder block and piston ring clearances.
13. Assemble the pistons.
14. Make sure the ring gaps (oil spacer-A, oil ring-B and compression ring-C) are correctly spaced around the circumference of the piston.





15. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only one connecting rod, rod bearing and piston shown.

Use the special tools to install the connecting rod with the upper connecting rod bearing in place.
^ Lubricate the piston and ring with clean engine oil.
^ Lubricate the rod bearings with clean engine oil.





16. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Once the connecting rod is seated on the crankshaft journal, remove the special tools.





17. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod and install the new bolts loosely.

18. NOTE: Main bearing caps shown removed for clarity.

Tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 43 Nm (32 ft. lbs.).
^ Stage 2: Tighten an additional 105 degrees.





19. Position the oil pump and install the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





20. Install the pickup tube spacer.
^ Tighten to 25 Nm (18 ft. lbs.).





21. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil.

Position the oil pump screen and pickup tube and install the bolts.
1 Tighten to 25 Nm (18 ft. lbs.).
2 Tighten to 10 Nm (89 inch lbs.).





22. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 cylinder head bolts loosely.





23. Tighten the LH cylinder head bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.





24. Tighten the RH cylinder head bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.





25. Remove the special tool from the LH cylinder head.





26. Remove the special tool from the RH cylinder head.





27. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

Install the hydraulic lash adjusters into the RH and LH cylinder heads.





28. NOTE: Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

Install the LH and RH camshafts.

29. NOTE: LH shown, RH similar.

NOTE: Lubricate the camshaft bearing caps with clean engine oil.

Install the LH and RH camshaft bearing caps in their original locations.
^ Position the front camshaft bearing cap.
^ Position the remaining camshaft bearing caps.
^ Install the bolts loosely.
^ Tighten to 10 Nm (89 inch lbs.) in the sequence shown.





30. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: LH shown, RH similar.

Position the camshaft phaser sprockets and install new camshaft phaser bolts finger-tight.





31. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: LH shown, RH similar.

Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





32. Install the crankshaft sprocket, making sure the flange faces forward.





33. Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o'clock position.





34. Rotate the camshaft sprockets to position the RH camshaft sprocket timing mark in the 11 o'clock position and the LH camshaft sprocket timing mark in the 12 o'clock position.





35. CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body, or permanent compression of the seal bead, will require installation of a new tensioner.

Inspect the RH and LH timing chain tensioners.
^ Install new tensioners as necessary.

36. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

Compress the tensioner plunger, using a vise.





37. Install a retaining clip on the tensioner to hold the plunger in during installation.





38. Remove the tensioner from the vise.
39. If the copper links are not visible, mark one link on one end and one link on the other end and use as timing marks.





40. Install the 4 bolts and the LH and RH timing chain guides.
^ Tighten to 10 Nm (89 inch lbs.).





41. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.





42. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link.





43. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





44. Remove the retaining clip from the LH timing chain tensioner.





45. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.





46. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.

NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.

Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link.





47. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





48. Remove the retaining clip from the RH timing chain tensioner.





49. NOTE: The RH and LH camshaft phaser sprockets are similar. Refer to the single timing mark to identify the RH camshaft phaser sprocket and the L timing mark to identify the LH camshaft phaser sprocket.

As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note.





50. Install the crankshaft sensor ring on the crankshaft.





51. NOTE: Lubricate the roller followers with clean engine oil prior to installation.

Using the special tool, install all of the camshaft roller followers.





52. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: If the engine front cover is 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.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.





53. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.





54. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).








55. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.





56. Using the special tools, install the crankshaft front oil seal into the engine front cover.





57. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.





58. Using the special tool, install the crankshaft pulley.





59. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.

60. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

NOTE: Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.

Position the coolant pump and install the 4 bolts loosely.