Part 1
Engine
Upper Engine
Timing Drive
Lower Engine
NOTICE: 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.
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.
All vehicles
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
2. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.
3. Tighten the 10 original main bearing beam bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 19 Nm (168 lb-in).
- Stage 2: Tighten an additional 60 degrees.
4. Measure each crankshaft block main bearing bore diameter.
5. Using the chart, select the crankshaft main bearings.
6. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
7. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
- Remove the bolts and the connecting rod cap.
- Discard the connecting rod cap bolts.
8. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
9. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
10. NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct orientation for reassembly.
Remove the 10 bolts in the sequence shown and the main bearing beam.
- Discard the main bearing beam bolts.
11. 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.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
NOTE: The center bulkhead is the thrust bearing.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
13. NOTE: Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.
14. Lubricate the 10 main bearing beam side fit surfaces and the 5 main bearing beam bearings with clean engine oil.
15. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
16. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.
Install and tighten the 10 new main bearing beam bolts.
- Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 19 Nm (168 lb-in).
- Stage 2: Tighten an additional 60 degrees.
17. 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 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
18. Make sure the dimple in the piston faces the front of the engine.
19. 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 arrow on top is facing toward the front of the engine.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
- When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
- The position of the upper and lower compression ring gaps are not controlled for installation.
20. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
Install the connecting rod caps and the new bolts and tighten the bolts in 3 stages.
- Stage 1: Tighten to 18 Nm (159 lb-in).
- Stage 2: Wait 2 seconds.
- Stage 3: Tighten an additional 35 degrees.
21. Install the Crankshaft Top Dead Center (TDC) Timing Pin and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC (Top Dead Center) Timing Pin. The engine is now at TDC (Top Dead Center).
22. Install a new gasket, the oil pump and the 8 bolts in their original position and tighten in sequence shown in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten to 9 Nm (80 lb-in).
23. Install the windage tray and the 4 bolts.
- Tighten to 9 Nm (80 lb-in).
24. Install the oil pump screen and pickup tube and 3 bolts.
- Tighten to 9 Nm (80 lb-in).
25. NOTE: New crankshaft rear seal is supplied with an alignment sleeve which must be removed after installation.
NOTE: Do not remove the alignment sleeve from the crankshaft rear seal prior to installation on the crankshaft.
NOTE: Do not lubricate the new crankshaft rear seal.
Align the crankshaft rear seal and alignment sleeve on the crankshaft and push the crankshaft rear seal off the alignment sleeve onto the crankshaft without stopping until the crankshaft rear seal meets the cylinder block.
- Install the 6 bolts and tighten in sequence shown in 2 stages.
- Stage 1: Tighten bolts 1 through 6 to 4 Nm (35 lb-in).
- Stage 2: Tighten bolts 1 through 6 to 9 Nm (80 lb-in).
26. Remove the alignment sleeve taking care not to touch the sealing lip.
27. NOTICE: 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
Clean and inspect all oil pan mating surfaces.
28. Install 2 M8x20 studs for oil pan alignment.
29. NOTE: The oil pan must be installed within 5 minutes of applying the sealant.
NOTE: If the oil pan is not secured within 5 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 3.5 mm (0.137 in) bead of sealant to the oil pan.
30. Install the oil pan using the 2 studs for alignment.
31. Install 11 bolts finger tight and remove the 2 alignment studs and install the remaining 2 bolts finger tight.
32. Tighten the oil pan bolts in the following sequence in 2 stages.
- Stage 1: Tighten bolts 1 through 13 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 1 through 13 to 20 Nm (177 lb-in).
33. NOTICE: 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
1. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
34. Install the cylinder head alignment dowels.
- Dowels must be fully seated in the cylinder block.
35. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the cylinder head gasket, cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 4 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 35 Nm (26 lb-ft).
- Stage 4: Turn 75 degrees.
36. NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.
37. If removed, install the camshaft trigger wheels and the 2 bolts.
- Tighten to 21 Nm (15 lb-ft).
38. NOTE: Lubricate the camshafts with clean engine oil.
Install the camshafts as shown.
39. Install the Variable Camshaft Timing (VCT) bridge O-ring seal.
40. NOTE: The VCT (Variable Camshaft Timing) bridge must be installed within 5 minutes of applying the gasket maker to the cylinder head.
Apply a 1.5 mm (0.059 in) bead of gasket maker to the cylinder head as shown.
41. NOTICE: Make sure that the camshafts and camshaft bearing caps are installed in their original locations or damage to the engine may occur.
NOTE: Apply clean engine oil to the bearing surfaces of the camshaft bearing caps and the VCT (Variable Camshaft Timing) bridge.
Install the camshaft bearing caps, VCT (Variable Camshaft Timing) bridge and the bolts finger tight.
42. Tighten the bolts in the sequence shown in 6 stages.
- Stage 1: Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT (Variable Camshaft Timing) bridge are seated against the cylinder head.
- Stage 2: Tighten bolts 1 through 16 to 7 Nm (62 lb-in).
- Stage 3: Tighten bolts 17 through 20 to 10 Nm (89 lb-in).
- Stage 4: Tighten bolts 1 through 16 an additional 45 degrees.
- Stage 5: Tighten bolts 17 and 19 an additional 70 degrees.
- Stage 6: Tighten bolts 18 and 20 an additional 53 degrees.
43. If the cylinder head, camshafts or valve tappets were replaced, check the valve clearance. For additional information, refer to Valve Clearance Check Adjustments.
44. Using the Camshaft Seal Installer, install the 2 camshaft oil seals.
45. NOTICE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon to align the camshafts.
Install the Camshaft Alignment Plate into the end of the camshafts.
46. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
NOTE: The timing marks of the camshaft phaser and sprocket must be at the 12 o'clock position.
Install the 2 camshaft phaser and sprocket, bolts and the VCT (Variable Camshaft Timing) Alignment Tool.
- Tighten the 2 bolts to 25 Nm (18 lb-ft).
47. Remove the VCT (Variable Camshaft Timing) Alignment Tool.
48. Remove the Camshaft Alignment Plate.
49. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Tighten to 2 camshaft phaser and sprocket bolts an additional 75 degrees.
50. NOTE: The special tool can only be installed if the valve timing is correct.
Install the Camshaft Alignment Plate into the end of the camshafts.
51. NOTE: The special tool can only be installed if the valve timing is correct.
Install the VCT (Variable Camshaft Timing) Alignment Tool.
- If the special tools cannot be installed, repeat the adjustment according to the preceding steps.
52. Remove the VCT (Variable Camshaft Timing) Alignment Tool.
53. Remove the Camshaft Alignment Plate.
54. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Install the 2 camshaft phaser and sprocket plugs.
- Tighten to 16 Nm (142 lb-in).
55. Install the VCT (Variable Camshaft Timing) Alignment Tool.
56. Install the 4 spark plugs.
- Tighten to 15 Nm (133 lb-in).
57. Using a new gasket, install the coolant pump, 6 bolts and tighten in sequence shown in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
58. Install the timing belt tensioner and the bolt.
- Tighten to 25 Nm (18 lb-ft).
- Rotate the timing belt tensioner clockwise and align the 2 holes on the tensioner and install a small screwdriver or holding pin.
59. NOTE: Lubricate the oil seal with clean engine oil.
Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Front Crankshaft Seal Replacer, install the crankshaft front oil seal.
