Part 1

ASSEMBLY

Assembly Note





1. Install the upper crankshaft main bearings.





2. Install the crankshaft.

NOTE: Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.





3. Install the crankshaft rear main oil seal.
1) Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with clean engine oil.
2) Position seal on SST 49 UN01 064. Position SST and seal to rear of engine. Alternate bolt tightening to seat seal properly.





4. Install the lower crankshaft main bearings.





5. Apply two dots of gasket eliminator or equivalent between the rear bearing cap and the cylinder block.





6. Wedge a large screwdriver at the location shown to hold the crankshaft forward until all the bolts are tightened.





7. Install the main bearing caps.

Main Torque Sequence:

8. Install the bolts.
1) Tighten the bolts in pairs.
2) For crankshaft and crankshaft bearing component tests, refer to Crankshaft Inspection and Bearing Inspection.





9. If removed, install the camshaft bearings.
- Use camshaft bearing set T65L-6250-A or equivalent.

10. Install the camshaft.





NOTE: Lubricate the camshaft and the camshaft bearings with clean engine oil.





11. Install the camshaft retainer.





12. Align timing marks.





13. Install the timing chain/belt, the camshaft sprocket and the crankshaft sprocket as an assembly.





14. Install the bolt.





15. Install the piston and connecting rod assemblies.
- Use a piston ring compressor.

NOTE: Lubricate the piston and connecting rod assemblies with clean engine oil.

16. Install the connecting rod bearings.

NOTE: Lubricate the connecting rod bearings with clean engine oil.

Connecting Rod:

17. Install the connecting rod caps and nuts.
1) Tighten the nuts in pairs.

Oil Pump:

18. Install the oil pump.





19. Install the valve tappets.

NOTE: Lubricate the valve tappets with clean engine oil.





20. Install the valve tappet guide plates.

Valve Tappet Guide Plate:

21. Install the valve tappet guide plate retainer.





22. Install the head gaskets.





23. Install the cylinder heads.

Head Bolt Torque Sequence:

24. Install the bolts. Tighten the bolts in the sequence shown in four steps.
1) Tighten the bolts to 80 Nm (59 ft. lbs.).
2) Loosen the bolts one full turn.
3) Tighten to 45 - 55 Nm (31 - 40 ft. lbs.).
4) Tighten to 85 - 99 Nm (63 - 73 ft. lbs.).





25. Install the oil bypass filter.





26. Install the oil level indicator tube.





27. Install the EGR valve to exhaust manifold tube.





28. Install the engine front cover gasket and the engine front cover.





29. Apply pipe sealant with Teflon on the bolts to be installed in the locations shown.

30. Install the bolts.

Front Cover Torque Sequence:

1) Tighten the bolts in the sequence shown.





31. Install the crankshaft position sensor (CKP sensor).





32. Apply four beads of silicone as shown.





33. Install the oil pan gasket.





34. Install the oil pan and hand-start the bolts.





35. Install the oil pan bolts.
1) Tighten the bolts in four steps.
- Tighten the four corner bolts to 10 - 14 Nm (89 - 123 inch lbs.).
- Tighten the remaining bolts to 10 - 14 Nm (89 - 123 inch lbs.).
- Loosen all the bolts one turn.
- Tighten all the bolts to 10 - 14 Nm (89 - 123 inch lbs.).