Steps 1 - 55
ASSEMBLYEngine
Special Tools And Equipment, Part 1:
Special Tools And Equipment, Part 2:
Special Tool(s)
Material:
Material
NOTE: Before assembling engine components, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.
All vehicles
1. Install the upper main bearings into the cylinder block and the lower main bearing into the crankshaft main bearing caps. Lubricate the main bearings with clean engine oil.
2. Install the crankshaft into the cylinder block.
3. CAUTION: Make sure the coated side of the thrust washer, with the 5-mm wide oil grooves, faces the crankshaft thrust surface.
Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.
4. Loosely install the main caps and the bolts.
5. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.
6. ighten bolts 1-20 in the sequence shown in 4 stages.
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
^ Stage 3: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
7. Install and tighten the cross-mounted bolts in 2 stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
8. Check the crankshaft end play.
9. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: Make sure that the piston arrow is facing forward.
NOTE: Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine oil.
Using the special tool, push the pistons through the top of the cylinder block.
10. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
NOTE: Make sure the crankshaft is at top dead center (TDC).
Using the special tool, install the connecting rod assemblies.
11. NOTE: The rod bearing cap bolts are torque-to-yield. Install new bolts each time they are serviced.
Install the connecting rod bearing caps and bolts and tighten in 3 stages.
^ Stage 1: Tighten to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten to 45 Nm (33 ft. lbs.).
^ Stage 3: Tighten an additional 90 degrees.
12. Check the connecting rod bearing clearance.
13. Install the spacers and the windage tray.
^ Tighten to 25 Nm (18 ft. lbs.).
14. Install and tighten the oil pump screen spacer.
^ Tighten to 25 Nm (18 ft. lbs.).
15. Position the oil pump, and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
16. NOTE: Install a new 0-ring if necessary.
Install the oil pump screen cover and tube.
^ Tighten the oil pump orifice bolts to 10 Nm (89 inch lbs.).
^ Tighten the pickup base bolt to 25 Nm (18 ft. lbs.).
17. Install the cylinder head gaskets.
18. NOTE: LH shown; RH similar.
NOTE: Lubricate the bolt heads and threads.
Use clean engine oil.
Install the LH and RH cylinder heads and tighten the bolts in 6 stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Loosen the bolts a minimum of one full turn.
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees.
^ Stage 6: Tighten an additional 90 degrees.
Engines with ratcheting timing chain tensioner
19. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
NOTE: LH shown, RH similar.
Compress each tensioner plunger, using an edge of a vise.
20. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
21. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
22. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
^ Remove the tensioner from the vise.
Engines with non-ratcheting timing chain tensioners
23. CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body or permanent compression of the seal bead, will require replacement of the tensioner.
Inspect the RH and LH timing chain tensioners.
^ Install new tensioners as necessary.
24. Compress the tensioner plunger, using a vise.
25. Install a retaining clip on the tensioner to hold he plunger in during installation.
26. Remove the tensioner from the vise.
All engines
27. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
28. Install the timing chain guides.
29. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is at approximately the 11 o'clock position.
30. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Using the special tool, position the crankshaft.
^ Remove the special tool.
31. Install the crankshaft sprocket with the flange facing forward.
32. Install the LH and RH timing chains onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
33. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the LH and RH timing chains on the camshaft sprockets. Make sure the copper-colored links align with the camshaft sprocket timing marks.
34. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
Engines with ratcheting timing chain tensioners
35. Remove the retaining clip from the timing chain tensioners.
36. Remove the retaining clips from the timing chain tensioners.
All vehicles
37. As a post-check, verify correct alignment of all timing marks.
38. Position the crankshaft sensor ring on the crankshaft.
39. Install the oil pan and gasket and loosely install he bolts.
40. Tighten the bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Rotate an additional 60 degrees.
41. Install the drain plug.
^ Tighten to 14 Nm (10 ft. lbs.).
42. NOTE: If the engine front cover is not secured within 4 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 4 minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
Apply silicone gasket and sealant in the locations shown.
43. Install the engine front cover. Tighten in the sequence shown to 25 Nm (18 ft. lbs.).
44. Install the 4 oil pan bolts and tighten in 3 stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 60 degrees.
45. Using the special tool, install the 32 roller followers.
46. NOTE: If the valve cover is not secured within 4 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 4 minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
Apply silicone gasket and sealant in the locations shown.
47. NOTE: RH shown; LH similar.
Install the valve covers and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
48. Install the belt idler pulley.
^ Tighten to 25 Nm (18 ft. lbs.).
49. Lubricate the front oil seal and the engine front cover with clean engine oil.
50. Using the special tools, install the front oil seal.
51. Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
52. Using the special tool, install the crankshaft pulley.
53. Install the special tool.
54. Install the bolt and washer. Tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen the bolt one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
55. NOTE: Lubricate the 0-ring seal with clean engine coolant. Use the same type of coolant hat was drained from the system.
Install the coolant pump and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).