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ENGINEAssembly
Warning: Eye protection is required to be worn during the use of compressed air. Failure to wear eye protection could result in possible personal injury.
1. 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. Select the crankshaft main bearings for each crank-shaft journal.
1. Read the code on the crankshaft flange.
2. Read the code on the cylinder block rear face.
3. The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2.
4. 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.
Note: This procedure is for selecting bearings using a new crankshaft.
1. For example: If the block code is *0609*0711* and the crankshaft code is *8480*8082*, main. No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 84 crankshaft row. Mains 2,3 and 4 should all be grade 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.
Caution: The lower cylinder block must be installed and the bolts tightened within four minutes of applying the sealant.
8. Apply Silicone Gasket and Sealant to the cylinder block as shown.
9. Apply SAE 5W-20 motor oil to the crankshaft main and rod bearing journals.
10. Position the crankshaft in the cylinder block.
Caution: Fasteners No. 1, 5, 6, 7, 8 are studs. Fasteners No. 18-22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 inch) bolts. Fasteners No. 2-4,17 are M8 x 1.25 mm x 95.3 mm (0.05 in x 3.75 inch) bolts. Fasteners 9-16 are M10 x 1.5 mm x 106 mm (0.06 in x 4.17 inch) bolts. The bolts and studs must be installed in the correct position or engine damage may result.
11. Position the lower cylinder block and install the bolts and studs.
1. Tighten the bolts and studs in the sequence shown in four stages.
2. Stage 1: Tighten fasteners 1-8 to 25 Nm (18 ft. lbs.).
3. Stage 2: Tighten fasteners 9-19 to 40 Nm (30 ft. lbs.).
4. Stage 3: Tighten fasteners 1-16 90°.
5. Stage 4: Tighten fasteners 17-22 to 25 Nm (18 ft. lbs.).
12. Using the special tool, measure the crankshaft end play.
13. Using the special tool, install the crankshaft rear oil seal.
14. Position the flexplate and install the bolts.
15. Mount the engine on an engine stand.
16. Apply SAE 5W-20 motor oil to the cylinder bores.
17. Using the special tools, install the piston and connecting rod assemblies.
18. Install the connecting rod caps and bolts.
1. Tighten the bolts in two stages.
2. Stage 1: Tighten to 23 Nm (17 ft. lbs.).
3. Stage 2: Tighten to 43 Nm (32 ft. lbs.).
19. Position the oil pump and install the bolts in the in dedicated sequence.
20. Position the oil pan baffle and install the nuts.
1. Tighten the nuts in two stages.
2. Stage 1: Tighten to 5 Nm (44 inch lbs.).
3. Stage 2: Tighten 45°.
21. Install a new O-ring seal on the oil pump screen and pick-up tube.
22. 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.
1. Tighten the nut in two stages.
2. Stage 1: Tighten to 5 Nm (44 inch lbs.).
3. Stage 2: Tighten 45°.
Note: LH shown, RH similar.
23. Position the LH and RH cylinder heads, gaskets, and install the bolts.
1. Tighten the bolts in the sequence shown in six stages.
2. Stage 1: Tighten to 40 Nm (30 ft. lbs.).
3. Stage 2: Tighten to 90 Nm (66 ft. lbs.).
4. Stage 3: Loosen one full turn.
5. Stage 4: Tighten to 40 Nm (30 ft. lbs.).
6. Stage 5: Tighten 90°.
7. Stage 6: Tighten 90°.
24. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o'clock position to locate Top Dead Center (TDC).
25. Apply SAE 5W-20 motor oil to the LH and RH camshaft followers.
Caution: The camshaft followers must be installed in the original position.
Note: RH shown, LH similar.
26. Install the LH and RH camshaft followers.
27. Apply SAE 5W-20 motor oil to the LH and RH camshafts.
28. Install the LH and RH camshafts.
1. Locate the camshafts as shown.
29. Position the LH camshaft caps and install the bolt in the sequence shown.
Caution: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.
30. Position the RH camshaft caps and install the bolts in the sequence shown.
31. Remove the crankshaft damper bolt.
32. Install the crankshaft sprockets.
Note: LH shown, RH similar.
33. Position the chain tensioner in a soft-jawed vise.
Note: LH shown, RH similar.
34. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
Caution: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
35. Slowly compress the timing chain tensioner.
36. Retain the tensioner piston with a 1.5 mm (0.06 inch) wire or paper clip.
37. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
1. Mark any link to use as the crankshaft timing mark.
2. Count 29 links from the crankshaft timing mark and mark as the exhaust cam sprocket timing mark.
3. Continue counting to 42 mark the link as the intake sprocket timing mark.
38. Position the LH timing chain and guide and install the bolts.
1. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
39. Install the LH timing chain tensioner and tensioner arm.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the bolts.
40. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o'clock position.
41. Verify that the RH camshafts are correctly positioned.
42. Position the RH timing chain and chain guide and install the bolts.
1. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
43. Install the RH timing chain tensioner and tensioner arm.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the bolts.