CONNECTING ROD NUT/BOLT Connecting Rod Bolt First Pass 25 Nm (18 lb ft) Final Pass Connecting Rod Bore Diameter Bearing End 100 degrees 52.118-52.134 mm (2.0519-2.05252 in) Pin End 23.007-23.017 mm (0.9058-0.9062 in) Connecting Rod Side Clearance Connecting Rod Straightness Bend - Maximum 0.070-0.370 mm (0.0028-0.0146 in) 0.021 mm (0.0083 in) Twist - Maximum 0.04 mm (0.0157 in) Connecting Rod Journal Diameter 49.000-49.014 mm (1.9291-1.9297 in) CONNECTING ROD BEARING CLEARANCE Connecting Rod Bearing Clearance 0.029-0.073 mm (0.0011-0.0029 in) Crankshaft Main Journal Diameter 55.994-56.008 mm (2.2045-2.2050 in) Crankshaft End Play 0.050-0.380 mm (0.0012-0.0150 in) MAIN BEARING CAP Crankshaft Bearing - Lower Crankcase to Block - Bedplate First Pass 20 Nm (15 lb ft) Final Pass 77 degrees Crankshaft Main Bearing Bore Diameter 64.068-64.082 mm (2.5224-2.5229 in) Crankshaft Main Bearing Clearance 0.031-0.067 mm (0.0012-0.0026 in) CYLINDER HEAD SURFACE VARIATION Surface Flatness - Block Deck Longitude 0.050 mm (0.002 in) Overall 0.1 mm (0.004 in) Transverse CYLINDER BLOCK 0.030 mm (0.0012 in) Cylinder Head Deck Surface Flatness Longitude 0.050 mm (0.002 in) Overall 0.10 mm (0.0039 in) Transverse CYLINDER BORE DIAMETER 0.030 mm (0.0012 in) Cylinder Bore Diameter CYLINDER BORE TAPER Cylinder Bore Taper Maximum CYLINDER OUT OF ROUND 85.992-86.008 mm (3.3880-3.3887 in) 0.010 mm (0.0004 in) Cylinder Bore Out-of-Round Maximum 0.010 mm (0.0004 in) CRANKSHAFT JOURNAL DIAMETER & LIMIT Crankshaft Main Journal Diameter 55.994-56.008 mm (2.2045-2.2050 in) Crankshaft Main Bearing Bore diameter 64.068-64.082 mm (2.5224-2.5229 in) Crankshaft End Play CRANKSHAFT MAIN BEARING CLEARANCE 0.050-0.380 mm (0.0012-0.0150 in) Crankshaft Main Bearing Clearance MAIN BEARING CAP 0.031-0.067 mm (0.0012-0.0026 in) Crankshaft Bearing - Lower Crankcase to Block - Bedplate First Pass 20 Nm (15 lb ft) Final Pass 77 degrees CONNECTING ROD BEARING CLEARANCE Connecting Rod Bearing Clearance Connecting Rod Bore Diameter Bearing End 0.029-0.073 mm (0.0011-0.0029 in) 52.118-52.134 mm (2.0519-2.05252 in) Pin End 23.007-23.017 mm (0.9058-0.9062 in) Connecting Rod Side Clearance Connecting Rod Straightness Bend - Maximum 0.070-0.370 mm (0.0028-0.0146 in) 0.021 mm (0.0083 in) Twist - Maximum 0.04 mm (0.0157 in) Connecting Rod Journal Diameter PISTON CLEARANCE 49.000-49.014 mm (1.9291-1.9297 in) Piston to Bore Clearance PISTON RING END GAP First Compression Ring 0.010-0.041 mm (0.0004-0.0016 in) 0.20-0.35 mm (0.0078-0.0138 in) Second Compression Ring 0.35-0.55 mm (0.014-0.022 in) Oil Control Ring - Rails PISTON RING TO GROOVE CLEARANCE First Compression Ring 0.25-0.75 mm (0.010-0.030 in) 0.040-0.080 mm (0.0016-0.0031 in) Second Compression Ring 0.003-0.068 mm (0.0001-0.0027 in) Oil Control Ring PISTON RING THICKNESS First Compression Ring 0.024-0.176 mm (0.0009-0.0069 in) 1.170-1.190 mm (0.0461-0.0469 in) Second Compression Ring 1.471-1.490 mm (0.0579-0.0587 in) Oil Control Ring - Rail - Maximum 0.473 mm (0.0186 in) Oil Control Ring - Spacer 0.96-1.04 mm (0.0378-0.0409 in) PISTON RING GROOVE WIDTH Oil Control 2.001-2.003 mm (0.0788-0.0789 in) Second 1.52-1.54 mm (0.0598-0.0606 in) Top PISTON DIAMETER 1.23-1.25 mm (0.0484-0.0492 in) Piston Diameter - @14.5 mm up CRANKSHAFT PULLEY 85.967-85.982 mm (3.3845-3.3851 in) Crankshaft Balancer Bolt First pass 100 Nm (74 lb ft) Final pass 125 degrees Cylinder Head Bolt First Pass First Pass CYLINDER HEAD BOLT RE-USABILITY 30 Nm (22 lb ft) 155 degrees Note: Do not use any sealing material. Always use NEW cylinder head bolts. INTAKE MANIFOLD Intake Manifold to Cylinder Head Bolt 22 Nm (16 lb ft) Intake Manifold to Cylinder Head Nut CAMSHAFT BEARING CAP 22 Nm (16 lb ft) Camshaft Cap Bolt MAIN BEARING CAP 10 Nm (89 lb in) Crankshaft Bearing - Lower Crankcase to Block - Bedplate First Pass 20 Nm (15 lb ft) Final Pass ROD BEARING CAP Connecting Rod Bolt First Pass Final Pass CRANKSHAFT PULLEY Crankshaft Balancer Bolt First pass Final pass FLYWHEEL/FLEXPLATE Flywheel Bolt - Automatic Transmission First Pass 77 degrees 25 Nm (18 lb ft) 100 degrees 100 Nm (74 lb ft) 125 degrees 53 Nm (39 lb ft) Final Pass Flywheel Bolt - Manual Transmission First Pass 25 degrees Final Pass OIL PUMP 25 degrees Oil Pump Gerotor Cover Bolt EXHAUST MANIFOLD 53 Nm (39 lb ft) 6 Nm (53 lb in) Exhaust Manifold to Cylinder Head Nut WATER PUMP Water Pump Bolts Engine Oil with Filter Oil Pressure - minimum @ 1000 RPM 14 Nm (10 lb ft) 25 Nm (18 lb ft) 5.0 quarts 4.7 liters) ( 344.75-551.60 kPa (50-80 psi) ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Fuel Pressure (Key ON, Engine OFF) Should not decrease more than 34 kPa (5 psi) in 1 minute. 395-464 kPa (57-67 psi) CRANKSHAFT PULLEY Crankshaft Balancer Bolt First pass 100 Nm (74 lb ft) Final pass 125 degrees INTAKE MANIFOLD Bolt 22 Nm (16 lb ft) Nuts 22 Nm (16 lb ft) THROTTLE BODY Throttle Body Bolt 10 Nm (89 lb in) Throttle Body Nut 10 Nm (89 lb in) Oil Pump Cover Bolt 6 Nm (53 lb in) PISTON CLEARANCE Piston to Bore Clearance PISTON DIAMETER Piston Diameter - @14.5 mm up Cylinder Head and Components 0.010-0.041 mm (0.0004-0.0016 in) 85.967-85.982 mm (3.3845-3.3851 in) 1 - Camshaft Position Actuator Solenoid Valve - Intake 2 - Camshaft Position Actuator Solenoid Valve Bolt 3 - Camshaft Position Actuator Solenoid Valve Bolt 4 - Camshaft Position Actuator Solenoid Valve - Exhaust 5 - Upper Intake Manifold Sight Shield Grommet 6 - Ball Stud 7 - Upper Intake Manifold Sight Shield Grommet 8 - Turbocharger Coolant Feed Pipe Fitting 9 - Turbocharger Coolant Feed Hose Gasket 10 - Turbocharger Coolant Feed Hose Clamp 11 - Turbocharger Coolant Feed Hose 12 - Turbocharger Coolant Feed Hose Bolt 13 - Turbocharger Coolant Feed Hose Gasket 14 - Turbocharger Coolant Feed Hose Clamp 15 - Upper Intake Manifold Sight Shield Grommet 16 - Ball Stud 17 - Ignition Coil Bolt 18 - Ignition Coil Bolt Retainer 19 - Ignition Coil 20 - Spark Plug 21 - Camshaft Cover Bolt 22 - Camshaft Cover Bolt Retainer 23 - Oil Fill Cap 24 - Oil Fill Cap Seal 25 - Camshaft Cover 26 - Camshaft Cover Seal 27 - Camshaft Cover Seal 28 - Camshaft Cap Bolt 29 - Camshaft Cap 30 - Camshaft Cap 31 - Camshaft Cap 32 - Exhaust Camshaft 33 - Intake Camshaft 34 - Camshaft Position Sensor Bolt 35 - Camshaft Position Sensor 36 - Camshaft Position Sensor O-Ring 37 - Roller Finger Follower 38 - Hydraulic Lash Adjuster 39 - Roller Finger Follower 40 - Hydraulic Lash Adjuster 41 - Cylinder Head Bolt 42 - Coolant Air Bleed Fitting 43 - Valve Keys 44 - Valve Spring Retainer 45 - Valve Spring 46 - Valve Stem Seal 47 - Small Cylinder Head Bolt 48 - Cylinder Head 49 - Timing Chain Guide Bolt Access Hole 50 - Exhaust Valve 51 - Intake Valve 52 - Camshaft Position Sensor Bolt 53 - Camshaft Position Sensor - Intake 54 - Camshaft Position Sensor O-Ring 55 - Cylinder Head Gallery Plug 56 - Rear Lift Bracket 57 - Rear Lift Bracket Bolt 58 - Cylinder Head Cover Plate Seal 59 - Cylinder Head Cover Plate 60 - Cylinder Head Cover Plate Bolt 61 - Fuel Injector Seal 62 - Fuel Injector 63 - Fuel Injector O-Ring 64 - Fuel Injector Hold Down Clamp 65 - Fuel Rail 66 - Fuel Rail Pressure Sensor 67 - Fuel Injector Wiring Harness 68 - Fuel Rail Bolt Intake Manifold and Components 1 - Evaporative (EVAP) Emission Purge Solenoid Valve Bolt 2 - EVAP Purge Solenoid Valve 3 - Manifold Absolute Pressure (MAP) Sensor Bolt 4 - MAP Sensor 5 - Fuel Pump Lifter 6 - High Pressure Fuel Pump Gasket 7 - High Pressure Fuel Pump O-Ring 8 - High Pressure Fuel Pump 9 - High Pressure Fuel Pump Bolt 10 - Fuel Feed Line 11 - Fuel Feed Line Bolt 12 - High Pressure Fuel Pump Insulator 13 - High Pressure Fuel Pump Cover 14 - High Pressure Fuel Line 15 - Fuel Injector Insulator 16 - Oil Indicator Tube 17 - Oil Indicator 18 - Intake Manifold Brace 19 - Intake Manifold Brace Stud 20 - Oil Indicator O-Ring 21 - Charger AIR Bypass Tube Clamp 22 - Charger AIR Bypass Tube Assembly 23 - Charger AIR Bypass Valve Tank Assembly Nut 24 - Charger AIR Bypass Valve Tank Assembly, Some Models 25 - Charger AIR Bypass Valve Solenoid Bolt 26 - Charger AIR Bypass Valve Solenoid 27 - Throttle Body Bolt 28 - Throttle Body 29 - Throttle Body Seal 30 - Power Brake Booster Fitting 31 - Intake Manifold 32 - Intake Manifold Gasket Exhaust Manifold and Components 1 - Turbocharger Wastegate Regulator Solenoid Hose 2 - Turbocharger Wastegate Regulator Solenoid Hose Clamp 3 - Turbocharger Wastegate Regulator Solenoid Hose 4 - Turbocharger Wastegate Regulator Solenoid Valve Assembly 5 - Turbocharger Wastegate Regulator Solenoid Valve Bracket 6 - Turbocharger Wastegate Regulator Solenoid Valve Bracket Bolt/Screw 7 - Turbocharger Wastegate Regulator Solenoid Hose 8 - Turbocharger Wastegate Regulator Solenoid Hose Clamp 9 - Turbocharger Oil Feed Pipe 10 - Turbocharger Oil Feed Pipe Bolt 11 - Turbocharger Oil Feed Pipe Gasket 12 - Turbocharger Oil Feed Pipe Gasket 13 - Turbocharger Oil Feed Pipe Bolt 14 - Turbocharger Coolant Return Pipe Gasket 15 - Turbocharger Coolant Return Pipe Bolt 16 - Turbocharger Coolant Return Pipe 17 - Turbocharger Coolant Return Pipe Bolt 18 - Turbocharger Coolant Return Pipe Gasket 19 - Turbocharger Coolant Feed Pipe 20 - Turbocharger Coolant Feed Pipe Gasket 21 - Turbocharger Coolant Feed Pipe Bolt 22 - Engine Coolant Heater 23 - Engine Coolant Heater Bolt 24 - Exhaust Manifold Heat Shield Bolt 25 - Exhaust Manifold Heat Shield Bolt 26 - Exhaust Manifold Heat Shield 27 - Exhaust Manifold Nut 28 - Exhaust Manifold 29 - Exhaust Manifold Gasket 30 - Exhaust Manifold Stud 31 - Oxygen Sensor Fastener 32 - Oxygen Sensor 33 - Oxygen Sensor Gasket 34 - Turbocharger Exhaust Pipe Heat Shield Bolt 35 - Turbocharger Exhaust Pipe Heat Shield 36 - Turbocharger Exhaust Pipe Nut 37 - Turbocharger Exhaust Pipe 38 - Turbocharger Exhaust Pipe Seal 39 - Turbocharger Exhaust Pipe Bolt 40 - Turbocharger Exhaust Pipe Stud 41 - Turbocharger Brace Nut 42 - Turbocharger Brace Bracket 43 - Turbocharger Brace Stud 44 - Turbocharger Brace 45 - Turbocharger Brace Bracket Bolt 46 - Turbocharger Brace Bracket 47 - Turbocharger Brace Bracket Stud 48 - Turbocharger Brace Nut 49 - Turbocharger Brace Bracket Bolt 50 - Turbocharger Brace Bracket Bolt 51 - Turbocharger Gasket 52 - Turbocharger 53 - Turbocharger Air Bypass Valve Spring 54 - Turbocharger Air Bypass Diaphragm Assembly 55 - Turbocharger Oil Return Pipe O-Ring 56 - Turbocharger Oil Return Pipe 57 - Turbocharger Oil Return Pipe Bolt 58 - Turbocharger Oil Return Pipe Gasket 59 - Turbocharger Air Bypass Valve Cover Bolt 60 - Turbocharger Air Bypass Valve Cover 61 - Turbocharger Exhaust Pipe Stud 62 - Turbocharger Air Cooler Outlet Pipe Seal 63 - Turbocharger Air Cooler Outlet Pipe 64 - Turbocharger Air Cooler Outlet Pipe Bolt 65 - Turbocharger Heat Shield 66 - Turbocharger Heat Shield Bolts Engine Block and Components 1 - Water Pump to Engine Block Seal 2 - Water Pump Seal 3 - Water Pump 4 - Water Pump Bolt 5 - Outlet Pipe O-rings 6 - Outlet Pipe 7 - Coolant Thermostat Housing Bolt 8 - Coolant Thermostat Housing 9 - Thermostat Housing to Block Gasket 10 - Coolant Thermostat Housing Seal 11 - Coolant Temperature Sensor 12 - Thermostat 13 - Coolant Inlet 14 - Coolant Inlet Bolt 15 - Water Pipe Support Bracket 16 - Water Pipe Support Bracket Bolt 17 - Water Pipe Support Bracket Bolt Stud 18 - Piston Ring Assembly 19 - Piston Assembly 20 - Connecting Rod Bushing 21 - Connecting Rod 22 - Connecting Rod Bearing 23 - Connecting Rod Cap Bolt 24 - Oil Cooler O-ring 25 - Oil Cooler 26 - Oil Cooler Bolt 27 - Front Lift Bracket 28 - Front Lift Bracket Bolt 29 - Cylinder Head Gasket 30 - Cylinder Bore Liner 31 - Cylinder Head Alignment Pin 32 - Oil Filter Cap 33 - Oil Filter Cap O-ring 34 - Oil Filter 35 - Engine Block Gallery Plug 36 - Engine Block to Transaxle Alignment Pin 37 - Crankshaft Position Sensor 38 - Crankshaft Position Sensor Bolt 39 - Oil Pressure Switch 40 - Piston Oil Nozzle Assembly 41 - Manual Transaxle Flywheel to Crankshaft Bolt 42 - Flywheel - Manual Transaxle 43 - Automatic Transaxle Flywheel to Crankshaft Bolt 44 - Flywheel - Automatic Transaxle 45 - Crankshaft Rear Seal 46 - Engine Block 47 - Crankshaft Thrust Bearing - Upper 48 - Crankshaft Bearing - Upper 49 - Crankshaft 50 - Crankshaft Thrust Bearing - Lower 51 - Crankshaft Bearing - Lower 52 - Lower Crankcase Main Bearing Bolt 53 - Lower Crankcase Perimeter Bolt 54 - Engine Oil Pan 55 - Engine Oil Pan Alignment Pins 56 - Lower Crankcase Main Bearing Bolt 57 - Engine Oil Pan Drain Plug 58 - Engine Oil Pan Bolt 59 - Engine Oil Pan Long Bolt 60 - Knock Sensor - Rear 61 - Knock Sensor - Front 62 - Starter Bolt 63 - Starter Timing Chain and Components 1 - Timing Chain Tensioner Body 2 - Timing Chain Tensioner Seal 3 - Adjustable Timing Chain Guide 4 - Adjustable Timing Chain Guide Bolt 5 - Timing Chain 6 - Fixed Timing Chain Guide Bolt 7 - Fixed Timing Chain Guide 8 - Timing Chain Drive Sprocket 9 - Friction Washers 10 - Timing Chain Oil Nozzle Bolt 11 - Timing Chain Oil Nozzle 12 - Camshaft Position Actuator Bolt 13 - Intake Camshaft Position Actuator 14 - Camshaft Position Actuator Bolt 15 - Exhaust Camshaft Position Actuator 16 - Upper Timing Chain Guide 17 - Upper Timing Chain Guide Bolt 18 - Balance Shaft Drive Sprocket Bolts 19 - Exhaust Balance Shaft Drive Sprocket 20 - Intake Balance Shaft Drive Sprocket 21 - Exhaust Balance Shaft Bearing Carrier 22 - Intake Balance Shaft Bearing Carrier 23 - Exhaust Balance Shaft 24 - Intake Balance Shaft 25 - Balance Shaft Rear Bearing 26 - Water Pump Drive Sprocket Bolt 27 - Water Pump Drive Sprocket 28 - Balance Shaft Drive Chain Tensioner Assembly Bolt 29 - Balance Shaft Drive Chain Tensioner Assembly 30 - Adjustable Balance Shaft Drive Chain Guide Bolt 31 - Adjustable Balance Shaft Drive Chain Guide 32 - Balance Shaft Drive Chain 33 - Balance Shaft Drive Chain Guide Bolt 34 - Balance Shaft Drive Chain Guide 35 - Balance Shaft Drive Sprocket 36 - Balance Shaft Drive Chain Guide 37 - Balance Shaft Drive Chain Guide Bolt 38 - Engine Front Cover Alignment Pins 39 - Engine Front Cover Gasket 40 - Oil Pump Cover Bolt 41 - Oil Pump Cover 42 - Oil Pump Gear 43 - Oil Pump Inner Rotor 44 - Engine Front Cover 45 - Engine Front Cover Bolt 46 - Crankshaft Front Oil Seal 47 - Crankshaft Balancer 48 - Crankshaft Balancer Bolt 49 - Engine Front Cover Bolt 50 - Oil Pressure Relief Valve 51 - Oil Pressure Relief Valve O-Ring 52 - Water Pump Sprocket Access Cover Bolt 53 - Water Pump Sprocket Access Cover 54 - Water Pump Sprocket Access Cover Gasket 55 - Belt Tensioner Bolt 56 - Belt Tensioner Engine Mechanical Specifications Adhesives, Fluids, Lubricants, and Sealers Fastener Tightening Specifications Thread Repair Specifications Engine Block - Front View Engine Block - Back View Engine Block - Right Side View Engine Block - Bottom View Engine Block - Left Side View Engine Block - Top View Lower Crankcase - Front View Lower Crankcase - Back View Lower Crankcase - Bottom View Lower Crankcase - Right View Lower Crankcase - Left View Cylinder Head - Top View Cylinder Head - Intake Manifold Deck View Cylinder Head - Exhaust Manifold Deck View Cylinder Head - Front View Cylinder Head - Back View CYLINDER HEAD BOLTS Cylinder Head Bolt First Pass First Pass CYLINDER HEAD BOLT RE-USABILITY 30 Nm (22 lb ft) 155 degrees Note: Do not use any sealing material. Always use NEW cylinder head bolts. INTAKE MANIFOLD Intake Manifold to Cylinder Head Bolt 22 Nm (16 lb ft) Intake Manifold to Cylinder Head Nut CAMSHAFT BEARING CAP 22 Nm (16 lb ft) Camshaft Cap Bolt MAIN BEARING CAP 10 Nm (89 lb in) Crankshaft Bearing - Lower Crankcase to Block - Bedplate First Pass 20 Nm (15 lb ft) Final Pass ROD BEARING CAP Connecting Rod Bolt First Pass Final Pass CRANKSHAFT PULLEY Crankshaft Balancer Bolt 77 degrees 25 Nm (18 lb ft) 100 degrees First pass 100 Nm (74 lb ft) Final pass FLYWHEEL/FLEXPLATE 125 degrees Flywheel Bolt - Automatic Transmission First Pass Final Pass Flywheel Bolt - Manual Transmission First Pass Final Pass OIL PUMP 53 Nm (39 lb ft) 25 degrees 53 Nm (39 lb ft) 25 degrees Oil Pump Gerotor Cover Bolt EXHAUST MANIFOLD 6 Nm (53 lb in) Exhaust Manifold to Cylinder Head Nut WATER PUMP Water Pump Bolts 14 Nm (10 lb ft) 25 Nm (18 lb ft) Cleanliness and Care An automobile engine is a combination of many machined, honed, polished, and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces during initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated. When valve train components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Replacing Engine Gaskets Tools Required J 28410 Gasket Remover Gasket Reuse and Applying Sealants Do not reuse any gasket unless specified. Gaskets that can be reused will be identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service information. Separating Components Use a rubber mallet to separate components. Bump the part sideways to loosen the components. Bumping should be done at bends or reinforced areas to prevent distortion of parts. Cleaning Gasket Surfaces Remove all gasket and sealing material from the part using the J 28410 or equivalent. Care must be used to avoid gouging or scraping the sealing surfaces. Do not use any other method or technique to remove sealant or gasket material from a part. Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. These methods of cleaning can cause damage to the component sealing surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage. Assembling Components When assembling components, use only the sealant specified or equivalent in the service procedure. Sealing surfaces should be clean and free of debris or oil. Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly. Components requiring lubrication will be identified in the service procedure. When applying sealant to a component, apply the amount specified in the service procedure. Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when tightened. Tighten bolts to specifications. Do not overtighten. Separating Parts Important: Disassembly of the piston, press fit design piston pin, and connecting rod may create scoring or damage to the piston pin and piston pin bore. If the piston, pin, and connecting rod have been disassembled, replace the components as an assembly. Many internal engine components will develop specific wear patterns on their friction surfaces. When disassembling the engine, internal components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Separate, mark, or organize the following components: Piston and the piston pin Piston to the specific cylinder bore Piston rings to the piston Connecting rod to the crankshaft journal Connecting rod to the bearing cap A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry. Crankshaft main and connecting rod bearings Camshaft and valve lash adjusters Valve lash adjusters, lash adjuster guides, pushrods and rocker arm assemblies Valve to the valve guide Valve spring and shim to the cylinder head location Engine block main bearing cap location and direction Oil pump drive and driven gears Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant Pipe Joint Compound Important: 3 types of sealer are commonly used in engines. These are room temperature vulcanizing (RTV) sealer, anaerobic gasket eliminator sealer, and pipe joint compound. The correct sealer and amount must be used in the proper location to prevent oil leaks. DO NOT interchange the 3 types of sealers. Use only the specific sealer or the equivalent as recommended in the service procedure. Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where 2 non-rigid parts, such as the oil pan and the engine block, are assembled together. Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include the exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to Replacing Engine Gaskets (See: Replacing Engine Gaskets). Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when the bolt is tightened. Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be clean and dry. Tighten the bolts to specifications. Do not overtighten. RTV Sealer RTV sealant hardens when exposed to air. This type sealer is used where 2 rigid parts, such as the lower crankcase and the engine block, are assembled together. Do not use RTV sealant in areas where extreme temperatures are expected. These areas include the exhaust manifold, head gasket, or other surfaces where a gasket eliminator is specified. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to Replacing Engine Gaskets (See: Replacing Engine Gaskets). Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened. Assemble components while RTV is still wet, within 3 minutes. Do not wait for RTV to skin over. Tighten bolts to specifications. Do not overtighten. Tools and Equipment Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. These tools, or their equivalents, are specially designed to quickly and safely accomplish the operations for which they are intended. The use of these special tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners. To properly service the engine assembly, the following items should be readily available: Approved eye protection and safety gloves A clean, well lit, work area A suitable parts cleaning tank A compressed air supply Trays or storage containers to keep parts and fasteners organized An adequate set of hand tools Approved engine repair stand An approved engine lifting device that will adequately support the weight of the components Special Tools Parts Information OEM Part # Price 19181846 $3588.39 Mfg. Warranty Standard B 0.0 1.0 B 0.0 10.8 B 8.8 12.4 B 0.0 17.3 A 0.0 19.3 A 0.0 26.8 Engine Engine Assembly Labor Information Skill Level Engine Diagnose/Test Oil Leak, Diagnosis Replace Complete Assembly Without Transfer Of Parts Does Not Include: Transfer Of Any Part Of Engine Or Replacement Of Optional Equipment. Complete Assembly With Transfer Of Parts Includes: Transfer All Fuel & Electrical Units. Does Not Include: Transfer Of Optional Equipment. Long Block Includes: R&I Engine And Transfer All Necessary Components Not Supplied With Long Block. Short Block Includes: R&I Engine And Transfer All Necessary Parts. Overhaul/Rebuild Includes: Measure Cylinder Bores, Crankshaft & Pistons For Proper Size & Hone Cylinders. Renew Pistons, Rings, Pins, Main & Rod Bearings, Grind Valves & Tune-Up. Engine Engine Account | Vehicle | Contact | Exit
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