CONNECTING ROD NUT/BOLT Connecting Rod Bolt First Pass 25 Nm

CONNECTING ROD NUT/BOLT Connecting Rod Bolt First Pass 25 Nm
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


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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.

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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
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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
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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:
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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.
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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

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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:
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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
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