Steps 1-60

Part 1:

Part 2:

Special Tool(s)




Material

Assembly





1. CAUTION: Install new O-ring seals on the crankcase-to-head tube. It requires several hours after installation for the O-ring seals to relax back to their original size. If the tube assembly is installed before the O-ring seals have relaxed, damage to the O-ring seals can occur.

Install new O-ring seals on each end of the crankcase-to-head tube assemblies.





2. NOTE: Check alignment of the oil holes after installing the bearings

If removed, install the camshaft bearings.





3. CAUTION: The patch bolt is unique. Do not substitute or engine damage can occur.

NOTE: Apply High Strength Threadlocker to the threads prior to installation.

Install the eight piston cooling tubes and bolts.





4. CAUTION: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage can occur.

NOTE: Apply clean engine oil to the camshaft prior to installing.

Install the camshaft and gear assembly. Install the thrust plate mounting bolts.





5. NOTE: Apply clean engine oil to all the bearings.

Install the crankshaft upper bearings and the crankshaft upper thrust bearing.





6. Using the special tool, align the camshaft timing mark as shown.





7. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.

8. NOTE: Do not turn the crankshaft during the main bearing clearance check.

Position commercially available plastigage in the center of each main bearing bolt cap.





9. Install the lower bearings into the lower crankcase.





10. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.

Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in the following sequence:
1 Tighten bolts to 122 Nm (90 ft. lbs.) in numerical sequence.
2 Tighten bolts again to 163 Nm (120 ft. lbs.) in numerical sequence.
3 Tighten bolts to 231 Nm (170 ft. lbs.) in numerical sequence.





11. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.





12. Remove the 28 bolts and the lower crankcase.





13. Measure the clearances for the main bearings. Remove the plastigage.





14. NOTE: Apply clean engine oil to the lower main bearings.

Install new lower crankcase seals.





15. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.

Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten mounting bolts in the following sequence:
1 Tighten bolts to 122 Nm (90 ft. lbs.) in numerical sequence.
2 Tighten bolts again to 163 Nm (120 ft. lbs.) in numerical sequence.
3 Tighten bolts to 231 Nm (170 ft. lbs.) in numerical sequence.





16. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.





17. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.

Install the special tool and measure the crankshaft end play.





18. Install the special tool and measure the camshaft end play.





19. Install the special tool and measure the camshaft gear backlash.





20. Install the block heater.





21. Install the Camshaft Position (CMP) sensor and the bolt.





22. Install the Crankshaft Position (CKP) sensor and the bolt.





23. NOTE: Lubricate with clean engine oil.

Install the connecting rod bearings.





24. NOTE: Make sure the ring openings are 120 degrees from each other, or engine damage can occur.

Install new piston rings.
1 The top compression ring is identified with one indentation mark and a 15-degree keystone profile.
2 The intermediate compression ring is identified with two indentation marks and a square profile.
3 Install the oil control ring.





25. NOTE: Cam V8 is toward the inside of the engine.

NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.

Install the piston and rod assemblies.
1 Coat the inside diameter of the ring compressor with clean engine oil.
2 Insert the piston into the special tool. Position the piston, connecting rod and special tool into the correct cylinder bore.
^ Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.





26. Position a piece of plastigage across the bearing surface.





27. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
^ Tighten to 45 Nm (33 ft. lbs.).
^ Tighten to 68 Nm (50 ft. lbs.).
28. Remove the bolts and the connecting rod cap.





29. Measure the clearances for the connecting rod cap. Remove the plastigage.





30. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
^ Tighten to 45 Nm (33 ft. lbs.).
^ Tighten to 68 Nm (50 ft. lbs.).





31. Using a feeler gauge, check for the minimum connecting rod side clearance.





32. Install the upper oil pan.
^ Install the upper oil pan gasket.
^ Install the upper oil pan.
^ Install the bolts.





33. CAUTION: To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.

NOTE: Only the front guides use bolts.

Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guide and the bolts.





34. NOTE: Right side shown, left side similar.

Install the rear engine tube assembly bolts.
^ Position the rear engine tube assembly and install the right side bolt hand tight.
^ Install the left side bolt hand tight.
^ Tighten both rear engine tube assembly bolts.





35. Install the four cylinder head dowels.





36. NOTE: Install a new cylinder head gasket with the part number facing upward. Verify the top five bolt holes and the head gasket push rod holes line up.

NOTE: Use care to avoid scratching the blue compound on the cylinder head gaskets.

Place the new cylinder head gaskets over the dowel sleeves and onto the crankcase.





37. Using the special tool, install the cylinder heads.
1 Install the lifting bracket.
2 Install the bolts.
^ Install the cylinder heads.





38. Install the 10 outer head bolts (finger-tight).





39. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.

NOTE: Higher mileage engines require push rods to be cleaned so the copper-colored end of the push rod can be identified.

Apply clean engine oil to each end of the push rods. Insert them into their respective positions with the copper-colored end up.





40. NOTE: Coat the end of each valve stem with clean engine oil.

Install the 16 valve bridges.





41. Install the rocker arm carrier to the cylinder head.
^ Install the press-in-place gasket.
^ Install the rocker arm carrier.
^ Install the bolts.





42. NOTE: Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position.

NOTE: Apply clean engine oil to the top center of each valve bridge.

Install the rocker arm assemblies and the 16 bolts.





43. CAUTION: Using too much engine oil on the threads of the cylinder head bolts, can cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads can affect the true torque value of the bolts.

NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.

Install the new cylinder head retaining bolts finger-tight.





44. Tighten the head bolts in the following sequence:
1 Tighten bolts 1 through 10 to 88 Nm (65 ft. lbs.).
2 Tighten bolts 1, 3, 5, 7 and 9 to 115 Nm (85 ft. lbs.).
3 Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
4 Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
5 Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
6 Tighten bolts 11 through 15 to 24 Nm (18 ft. lbs.).
7 Tighten bolts 11 through 15 to 31 Nm (23 ft. lbs.).





45. CAUTION: To prevent engine damage, check that the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function if these tubes are not bottomed out.

Apply clean engine oil and install a crankcase-to-head tube assembly.





46. CAUTION: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.

NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.

Install new O-ring seals and a copper washer on the fuel injector.





47. CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.

Install the fuel injector, the fuel injector hold down and bolt.





48. CAUTION: Be sure the injector wiring is clear of all moving parts or engine damage can occur.

Install the fuel injector electrical connector into the rocker carrier.





49. NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.

Position the high-pressure oil rail on the injectors.
^ Place the high-pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle.
^ Insert three guide bolts, two on the ends of the straight side of the high-pressure oil rail and one in the middle of the wavy side of the high-pressure rail. Install the guide studs six to seven turns.
^ Press the high-pressure oil rail into the fuel injectors.
^ Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface.
^ Loosely install the six bolts.





50. Install the remaining bolts and tighten.
^ Remove the three guide bolts.
^ Loosely install the three remaining bolts.
^ Tighten the nine bolts in the sequence shown.





51. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.

NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.

NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.

Install the left exhaust manifold and the bolts.





52. NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.

NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.

NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.

Install the right exhaust manifold and the bolts.





53. Apply a bead of sealant at the back seam of the upper and lower crankcase.





54. Install the rear engine cover.
^ Install the press-in-place gasket.
^ Install the rear engine cover.
^ Install the bolts.





55. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.

NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant.

NOTE: Apply a bead of High Strength Threadlocker around the circumference of the outer rear edge of the secondary crankshaft flange.

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





56. Install the flywheel adapter.





57. If removed, install the front cover crankcase dowels into the cylinder block.





58. Apply a bead of sealant at the front seam of the upper and lower crankcase.





59. NOTE: Use guide spuds to aid in installation. Sheds must be fabricated locally.

Install the guide spuds and the front cover gasket.





60. Install the engine front cover and bolts.