Steps 1 - 40
Special Tools:
Special Tool(s)
Materials
Item: Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent
Specification: WSS-M2C153-H
Item: Gasket Maker FSAZ-19B508-AB or equivalent
Specification: WSK-M2G348-A5
Item: Pipe Sealant with Teflon D8AZ-19554-A or equivalent
Specification: WSK-M2G350-A2
Item: Silicone Gasket and Sealant F7AZ-19554-EA or equivalent
Specification: WSE-M4G323-A4
1. CAUTION: The crankshaft main bearings are precision fit.
Install the upper crankshaft main bearings.
2. NOTE: Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
Position the crankshaft.
3. NOTE: Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with clean engine oil.
Install the crankshaft rear oil seal.
4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block.
5. Install the lower crankshaft main bearings.
6. Install the main bearing caps.
7. Install the main bearing cap bolts in the sequence shown.
- Tighten the bolts in pairs.
- Carry out the crankshaft and crankshaft bearing component tests.
8. If removed, install the camshaft bearings.
9. NOTE: Lubricate the camshaft and the camshaft bearings with clean engine oil.
Install the camshaft.
10. Install the camshaft thrust plate.
11. Inspect the camshaft end play.
12. Align the timing marks.
13. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
14. Install the camshaft sprocket bolt.
15. NOTE: Lubricate the piston and connecting rod assemblies with clean engine oil.
Install the piston and connecting rod assemblies.
16. NOTE: Lubricate the connecting rod bearings with clean engine oil.
Install the connecting rod bearings.
17. Install the connecting rod caps and nuts.
- Tighten the nuts in pairs.
18. Install the oil pump.
19. NOTE: Lubricate the valve tappets with clean engine oil.
Install the valve tappets.
20. Install the valve tappet guide plates.
21. Install the valve tappet guide plate retainer.
22. Install new head gaskets.
23. Position the cylinder heads.
24. Install the bolts. Tighten the bolts in the sequence shown in five stages.
- Stage 1: Tighten the bolts to 50 Nm (37 inch lbs.).
- Stage 2: Loosen the bolts one full turn.
- Stage 3: Tighten to 30 Nm (22 ft. lbs.).
- Stage 4: Rotate 85 - 95°.
- Stage 5: Rotate an additional 85 - 95°.
25. Install the oil filter.
- Advance the filter one half turn after the gasket contacts the sealing surface.
26. Install a new engine front cover gasket and the engine front cover.
27. Install the engine front cover and water pump assembly.
1 Apply pipe sealant with Teflon to the bolts indicated.
2 Install the bolts.
28. Apply four beads of gasket maker as shown.
29. Position the oil pan gasket.
30. Position the oil pan and hand-start the bolts.
31. Install the bolts.
- Tighten the bolts in four stages:
- Stage 1: Tighten the four corner bolts to 12 Nm (9 inch lbs.).
- Stage 2: Tighten the remaining bolts to 12 Nm (9 inch lbs.).
- Stage 3: Loosen all the bolts one turn.
- Stage 4: Tighten all the bolts to 12 Nm (9 inch lbs.).
32. Install the camshaft synchronizer.
33. Apply four beads of silicone gasket and sealant.
34. Position the intake manifold gaskets and end seals.
35. Install the lower intake manifold.
- Tighten the bolts in two stages.
- Stage 1: Tighten to 15 Nm (18 ft. lbs.).
- Stage 2: Tighten to 32 Nm (24 ft. lbs.).
36. Install the push rods and the rocker arms.
- Install the push rods.
- Install the rocker arms.
- Tighten the bolts in two stages:
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Tighten to 32 Nm (24 ft. lbs.).
37. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
38. If removed, install the valve cover gaskets.
39. Install the LH valve rocker arm cover.
- Install the two bolts.
- Install the six stud bolts.
40. Install the RH valve rocker arm cover.
- Install the five bolts.
- Install the three stud bolts.