Steps 1-50

ASSEMBLY

Part 1:

Part 2:

Special Tool(s)





Material





1. CAUTION: The crankshaft main bearings are precision fit.

Install the crankshaft upper 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 seal with clean engine oil.

Install the crankshaft rear seal.





4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block.





5. Install the crankshaft lower 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 new 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 cylinder head gaskets.





23. Position the cylinder heads.





24. Install the bolts. Tighten the bolts in five stages in the sequence shown.
^ 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 90 degrees.
^ Stage 5: Rotate an additional 90 degrees.





25. Install the oil filter.





26. CAUTION: All timing marks must be aligned with the No. 1 cylinder set on top dead center (TDC) of the compression stroke or the synchronizer assembly will not be installed correctly.

NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.

Align the timing marks.





27. Install a new engine front cover gasket and the engine front cover.





28. Install the engine front cover and water pump assembly.
1 Apply pipe sealant with Teflon@ to the bolts indicated.
2 Install the bolts.





29. Apply four beads of gasket maker as shown.





30. Position the oil pan gasket.





31. Position the oil pan and hand-start the bolts.





32. NOTE: Make sure the fasteners are clean and dry prior to installation.

Tighten the oil pan bolts to 12 Nm (9 ft. lbs.) in the sequence shown.





33. CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center of the compression stroke on the No. 1 cylinder.

CAUTION: A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.

Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.





34. NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.

NOTE: During installation, the arrow on the synchronizer alignment gauge will rotate clockwise as the gears engage.

Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 38 degrees from the centerline of the engine.





35. Install the camshaft synchronizer retaining bolt.





36. Install the Camshaft Position (CMP) sensor.





37. NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply four beads of silicone gasket and sealant.





38. Position the intake manifold gaskets and end seals.





39. Install the lower intake manifold. Tighten the bolts in two stages in the sequence shown.
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 32 Nm (24 ft. lbs.).





40. CAUTION: If reusing the push rods and rocker arms, they must be installed in their original positions.

Install the push rods and the rocker arms. Tighten the rocker arm bolts in two stages
^ Stage 1: Tighten the bolts to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten the bolts to 32 Nm (24 ft. lbs.).





41. NOTE: If the valve covers are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.





42. If removed, install the valve cover gaskets.





43. Install the LH valve cover.





44. Install the RH valve cover.





45. Position a new exhaust manifold gasket and install the RH exhaust manifold.





46. Install the bolts. Tighten the exhaust manifold bolts in two stages in the sequence shown.
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten to 22 Nm (16 ft. lbs.).





47. Install the RH exhaust manifold heat shield.





48. Position and connect the RH spark plug wires.





49. Position a new exhaust manifold gasket and install the LH exhaust manifold.





50. Install the four bolts and two stud bolts. Tighten the exhaust manifold bolts in two stages in the sequence shown.
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten to 22 Nm (16 ft. lbs.).