CAUTION: Do not oil threads that require oil resistant or water resistant sealer.

When installing nuts or bolts, oil the threads with light weight engine oil.

Refer to Section 03-00 for Cleaning and Inspection procedures.

Engine

Tools Required:

• Rotunda Piston Ring Compressor 014-00290
• Rotunda Cylinder Ridge Reamer 014-00292

Disassembly

NOTE: Before starting disassembly, remove all wiring harnesses, emission control system, fuel system, ignition system, flywheel, rear cover plate and front end accessory drive components.

With engine mounted on a work stand:

1. Remove the upper and lower intake manifold assemblies as outlined in this section.

2. Remove the left and right hand rocker arm covers and discard the gaskets.

NOTE: All valve train components should be identified to ensure they are installed in their original positions during assembly.

3. Remove the oil dipstick and tube assembly and remove the oil filter.

4. Remove the valve rocker arms, fulcrums, push rods, guides and tappets and remove the cylinder heads as outlined.

5. Remove the crankshaft pulley and damper as outlined.

6. Remove the water pump and front cover as an assembly. Discard the gasket and seal.

7. Remove the oil pan and discard the gasket.

8. Remove the oil pump, pick-up tube and intermediate driveshaft.
   
   
   
   

9. Remove the rear crankshaft seal.

10. Remove the camshaft sprocket, capscrew and washer. Slide the sprocket and timing chain forward and remove the chain and sprocket as an assembly.
    
    
    
    

11. Remove the camshaft thrust plate and remove the camshaft.

    NOTE: Pistons, connecting rods and bearings should be numbered to ensure they are assembled in their original positions.

    NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Rotunda Cylinder Ridge Reamer 014-00292 or equivalent.

12. Remove the connecting rod caps and remove the pistons.

     CAUTION: When removing the crankshaft, take care not to damage any of the bearing surfaces on the crankshaft.

    NOTE: The location of the main bearing caps and the main bearing inserts should be identified. When the engine is assembled, bearings which are to be reused should be installed in their original positions.

13. Remove the crankshaft main bearing caps, bearings and crankshaft.

14. For cleaning purposes, the oil gallery and coolant drain plugs can be removed.

Assembly

Before assembling cylinder block, all sealing surfaces must be clean and free of chips, dirt, paint, and foreign material. Also, ensure coolant and oil passages are clear.

If new piston rings are to be installed and no visible cross hatch marks remain on the cylinder wall, remove cylinder wall glaze using a spring type tool. Follow instructions of tool manufacturer.

NOTE: Lightly oil all retaining bolt and stud threads before installation, except those specifying special sealant.

1. Place crankshaft upper main bearings in position in the bores with the tang fitting in the slot provided. Lubricate bearings with Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent.

2. Install the lower main bearings in the bearing caps.

3. Carefully lower crankshaft into place. Use care to prevent damage to bearing surfaces.

4. Check clearance of each main bearing, following the procedure under Fitting Main and Connecting Rod Bearings in Section 03-00.

5. After bearings have been fitted, apply a light coat of Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent to the journals and bearings.

    CAUTION: Ensure main bearing caps are installed in their original position.

6. Install all bearings and caps except thrust bearing cap (No. 3 bearing). Tighten bearing caps to 81-95 Nm (60-70 lb-ft).

   NOTE: Apply sealer Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent in a 1.59mm (1/16 inch) bead in each corner of rear main bearing cap saddle, and full length of the saddle.

7. Install thrust bearing cap (No. 3) with bolts finger tight.
   
   
   
   
   

   Item	Part Number	Description
   1	388813	Bolt 5/8-18
   2	6378	Damper Washer
   3	6312	Crankshaft Pulley
   4	6316	Crankshaft Damper
   5	6306	Crankshaft Sprocket
   6	388907	Crankshaft Key
   7	6300	Crankshaft
   8	6333	Crankshaft Main Upper Bearing
   9	6337	Crankshaft Main Upper Thrust Bearing
   10	6375	Flywheel Assy
   11	6701	Rear Oil Seal
   12	6A388	Crankshaft Main Lower Bearing
   13	6A339	Crankshaft Main Lower Thrust Bearing
   14	6325	Main Bearing Rear Cap
   15	6327	Main Bearing Rear Intermediate Cap
   16	6330	Main Bearing Center Cap
   17	6334	Main Bearing Front Intermediate Cap
   18	6329	Main Bearing Front Cap
   19	386562	Main Bearing Cap Stud
   20	391288	Main Bearing Cap Bolt (9 Req'd)
   21	—	Bolt (4 Req'd)

8. Pry crankshaft forward against thrust surface of upper half of bearing.

9. Hold crankshaft forward and pry thrust bearing cap to the rear. This will align thrust surfaces of both halves of the bearing.

10. Retain forward pressure on crankshaft. Tighten cap bolts to 81-95 Nm (60-70 lb-ft).

11. Force crankshaft toward the rear of engine.
    
    
    
    

12. Check crankshaft end play. Refer to Section 03-00.

13. Install crankshaft rear oil seal as outlined in this section. Install rear cover plate and flywheel. Tighten bolts to 102-115 Nm (75-85 lb-ft).

14. Coat all camshaft bearings, camshaft lobes and gear with Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent.

15. Carefully slide camshaft through camshaft bearings. Install camshaft thrust plate with groove toward cylinder block. Tighten thrust plate retaining bolts to 12-16 Nm (9-12 lb-ft).
    
    
    
    
    

    Item	Part Number	Description
    1	6256	Camshaft Sprocket
    2	6268	Timing Chain
    3	—	Camshaft Bearings
    4	6266	Camshaft Rear Bearing Bore Plug
    5	6250	Camshaft
    6	391269	Dowel Pin
    7	6269	Thrust Plate
    8	390392	Thrust Plate Bolt (2 Req'd)
    9	43002	Bolt
    10	6278	Flat Washer

16. Check camshaft end play. Refer to Section 03-00. If not within specification, replace thrust plate.

17. Install camshaft sprocket, timing chain and eccentric. Position sprocket and timing chain on camshaft and crankshaft sprocket simultaneously. Ensure timing marks on the sprockets are aligned.

18. Install washer and camshaft capscrew. Tighten camshaft capscrew.
    
    
    
    

19. Oil the piston rings, pistons and cylinder walls with clean engine oil XO-10W30-QSP (ESE-M2C153-E) or equivalent. Be sure to install the pistons in the same cylinders from which they were removed.

20. Ensure the ring gaps are properly spaced around the circumference of the piston. Refer to Piston and Connecting Rod Installation as outlined.

     CAUTION: Install piston with indentation notch in the piston head toward front of engine.

21. Install Rotunda Piston Ring Compressor 014-000290 or equivalent on the piston and push piston in with a hammer handle until it is slightly below top of cylinder. Be sure to guide connecting rods to avoid damaging crankshaft journals (cover studs).
    
    
    
    

22. Check clearance of each connecting rod bearing. Refer to procedure in Section 03-00.

23. After bearings have been fitted, apply a light coat of Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent to the journals and bearings.

24. Turn the crankshaft throw to the bottom of it's stroke. Push piston all the way down until connecting rod bearing seats on the crankshaft journal.

25. Install connecting rod cap. Tighten nuts to 26-32 Nm (19-24 lb-ft).

26. After piston and connecting rod assemblies have been installed, check side clearance between connecting rods on each crankshaft journal.
    
    
    
    

27. Prime the oil pump and install oil pump, intermediate shaft, and pick-up tube and screen assembly. Tighten oil pump bolts to 30-43 Nm (22-32 lb-ft).
    
    
    
    

28. Install crankshaft oil seal in front cover as outlined.

29. Install front cover seal, gasket, timing pointer and front cover. Tighten cover bolts to 16-24 Nm (12-18 lb-ft). (Refer to procedure in this section.) Also, install crankshaft damper and pulley and torque bolt to 95-122 Nm (70-90 lb-ft).

30. Install new oil filter.

31. Install oil pan gasket and seal assembly. Install oil pan. Tighten the 1/4 inch pan bolts to 9-14 Nm (80-120 lb-ft) and the 5/16 inch oil pan bolts to 16-24 Nm (12-18 lb-ft).

32. Install tappets in their original bores.

33. Install tappet guide plate and tighten screws and washers to 8-12 Nm (71-106 lb-in).

    NOTE: If cylinder heads were completely disassembled, refer to Cylinder Head Disassembly and Assembly as outlined.

34. Position cylinder head gaskets on cylinder block. Install cylinder head locating dowels. Install cylinder heads.

35. The cylinder head bolts are tightened in two or three steps depending upon the type of head bolt used. Two styles are available, flanged hex head or non-flanged (standard) hex head.
    
    
    
    

    Refer to the following illustration for the tightening sequence. For the non-flanged (standard) hex head bolts, tighten in two steps:

    1. Tighten all bolts in sequence to 75-88 Nm (55-65 lb-ft).
    2. Tighten all bolts in sequence to 88-98 Nm (65-72 lb-ft).

    If using the flanged hex head bolts, tighten in three steps:

    1. Tighten all bolts in sequence to 34-47 Nm (25-35 lb-ft).
    2. Tighten all bolts in sequence to 61-75 Nm (45-55 lb-ft).
    3. Tighten all bolts in sequence an additional 1/4 turn (85-95 degrees).

    NOTE: The right hand side cylinder head has one stud at location 8. The left hand side does not.

    
    
    
    
    

36. Install valve push rods, fulcrum guides or pedestal assemblies, rocker arms and fulcrums or roller rocker arm assemblies, and tighten fulcrum bolts to 24-34 Nm (18-25 lb-ft).

    NOTE: Sealer sets up in 15 minutes, so it is important that assembly be completed promptly.

37. Apply sealer at points shown and install intake manifold gaskets and seals.
    
    
    
    

38. Install lower and upper intake manifold. Use guide pins to ease installation of intake manifold onto cylinder head.

39. Tighten intake manifold bolts as outlined in this section.

40. Install oil dipstick tube and indicator assembly.

41. Position valve rocker arm cover gasket in each cover and install valve rocker arm covers. Install rocker arm cover bolts and tighten to 16-20 Nm (12-15 lb-ft).
    
    
    
    

42. Install wiring harnesses, emission control system, fuel system, and ignition system and front end accessory drive components. Refer to appropriate engine section.