Part 1 of 3

Engine Assembly (Part 1 of3)











Special Tool(s)





Material

All vehicles

1. WARNING: Eye protection is required to be worn during the use of compressed air. Failure to follow these instructions can result in personal injury.

Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.





2. If removed, install the crankshaft key into the keyway on the crankshaft.

3. NOTE: This procedure is for selecting bearings using a new crankshaft.





Select the crankshaft main bearings for each crankshaft journal.
1 Read the code on the crankshaft flange.
2 Read the code on the cylinder block rear face.
^ The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2.
^ The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.





4. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
^ For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be Trade 2.





5. Install the main bearings into the cylinder block.





6. Install the main bearings into the lower cylinder block.





7. Install the crankshaft thrust bearing.





8. If removed, install the crankshaft key.
9. Apply clean engine oil to the crankshaft main and rod bearing journals.

10. CAUTION: The lower cylinder block must be installed and the bolts tightened within four minutes of applying the sealant.

NOTE: Clean and decrease both surfaces using metal surface cleaner before applying sealant.





Apply gasket and sealant to the cylinder block as shown.





11. Position the crankshaft in the cylinder block.

12. CAUTION: Fasteners No. 5-8 are studs. Fasteners No. 18-22 are M8 x 1.25 mm x 79.3 mm (0.05 inch x 3.12 inch) bolts. Fasteners No. 1-4, 17 are M8 x 1.25 mm x 95.3 mm (0.05 inch x 3.75 inch) bolts. Fasteners 9-12 are M10 x 1.5 mm x 106.8 mm (0.06 inch x 4.20 inch)/M8 x 1.25 mm x 21.5 mm (0.05 inch x 0.84 inch studs. Fasteners 13-16 are M10 x 1.5 mm x 106 mm (0.06 inch x 4.17 inch) bolts. The bolts and studs must be installed in the correct position or engine damage can result.





Position the lower cylinder block and install the bolts and studs.
^ Tighten the bolts and studs in the sequence shown in four stages.
^ Stage 1: Tighten fasteners 1-8 to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten fasteners 9-16 to 40 Nm (30 ft. lbs.).
^ Stage 3: Tighten fasteners 1-16 90 degrees.
^ Stage 4: Tighten fasteners 17-22 to 25 Nm (18 ft. lbs.).





13. Using the special tool, measure crankshaft end play.





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





15. Position the flexplate and loosely install the bolts.
^ Install the special tool to hold the flexplate.





16. Tighten the flexplate bolts.
17. Mount the engine on an engine stand.

18. CAUTION: 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: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.





Using the special tools, install the piston and connecting rod assemblies.





19. Install the connecting rod caps and bolts.
^ Tighten the bolts in two stages.
^ Stage 1: Tighten to 23 Nm (17 ft. lbs.).
^ Stage 2: Tighten to 43 Nm (32 ft. lbs.).
20. Fill the oil pump with clean engine oil. Rotate the oil pump one revolution. Drain the engine oil.





21. Position the oil pump and install the bolts in the indicated sequence.





22. Position the oil pan baffle and install the nuts.
^ Tighten the nuts in two stages.
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten 45 degrees.





23. Install a new O-ring seal on the oil pump screen and pick-up tube and lubricate with clean engine oil.





24. Install the oil pump screen and pick-up tube.
1 Position the oil pump screen and pick-up tube.
2 Install the bolts.
3 Install the nut.
- Tighten the nut in two stages.
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Tighten 45 degrees.





25. Install the crankcase cover, a new gasket and the bolts.

26. NOTE: RH shown, LH similar.





Position the LH and RH cylinder heads and new gaskets. Install the bolts.
^ Tighten the bolts in the sequence shown in six stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 3: Loosen one full turn.
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten 90 degrees.
^ Stage 6: Tighten 90 degrees.





27. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
28. Apply clean engine oil to the LH and RH camshaft followers.

29. NOTE: RH shown, LH similar.





Install the LH and RH camshaft followers.
30. Apply clean engine oil to the LH and RH camshafts.





31. Install the LH and RH camshafts.
^ Locate the camshafts as shown.





32. Position the RH camshaft caps and install the bolts in the sequence shown.





33. Position the LH camshaft caps and install the bolts in the sequence shown.

34. CAUTION: The camshaft bearing caps are positional and must be installed in their original locations and orientations or engine damage can occur.





Verify that the camshaft bearing caps are in the correct locations.

35. NOTE: Clean and decrease the sealing surfaces with metal surface cleaner.





Install a new press-in-place gasket and install the camshaft oil seal retainer.

36. NOTE: Lubricate the camshaft oil seal with clean engine oil.





Install a new camshaft oil seal.
^ Using the special tools positioned over the oil seal, turn to install the seal.

37. CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 inch) past flush of the end of the camshaft. The service pulley gets pressed on flush to the end of the camshaft.





Using the special tool, install the coolant pump drive pulley.





38. Remove the crankshaft damper bolt.





39. Install the crankshaft sprockets with the timing marks facing outward.

40. NOTE: LH shown, RH similar.





Position the chain tensioner in a soft jawed vise.