assembly

95 crank shaft
Use a soft hammer to install the gear alignment dowel into the crankshaft.
Heat the gear in an oven for a minimum of 45 minutes, but not more than 2 hours
at 177C
Use assembly lube, Part Number or equivalent, to lubricate the outside diameter
of the crankshaft gear journal.
Remove the gear from the oven. engines the timing mark and part number on the ge
ar must be facing away from the crankshaft after the gear is installed

96 crank shaft
align the keyway of the gear with the alignment dowel pin in the crankshaft. Ins
tall the crankshaft gear within 30 seconds of removing it from the oven.
Make sure the gear is seated against the crankshaft shoulder. Use a 0.02 mm [0.0
01 in] feeler gauge to check to see if the feeler gauge can be inserted between
the crankshaft gear and the shoulder on the crankshaft. If the feeler gauge can
be inserted, the crankshaft gear is not properly seated and must be removed and
installed again.

97 crank shaft Install saddle jet piston cooling nozzles

Make sure the backsides of the bearings are clean and free of debris before inst
alling the upper main bearings into the block.
Make sure to align the tangs of the bearings with tangs on the main bearing bloc
k saddles.
Install the upper crankshaft thrust bearing.
4 cylinder engines - The number 4 main bearing position.
6 cylinder engines - The number 6 main bearing position.

98 crank shaft
Apply a coat of assembly lube, Part Number , to the crankshaft side of the main
bearings and thrust bearing surfaces.
Check the main bearing caps to make sure the ring dowels are installed.
Install the crankshaft.
Make sure the backsides of the bearings are clean and free of debris before inst
alling the lower main bearings into the main bearing caps.
Make sure to align the tangs of the bearings with tangs on the main bearing caps
.

99 crank shaft
The main bearing caps are/were numbered during the removal process for their loc
ation. Number 1 starts with the front of the block.
Lubricate the main bearing capscrew threads and underside of the head with clean
engine oil.
Gently tap the main bearing cap into position with a plastic or rubber mallet.
When seated, install the main bearing capscrews and tighten. Torque Value: 50 nm
Do not tighten to the final torque value at this time. Final torque should be ap
plied after all main bearing caps are installed.

100 crank shaft

Tighten the capscrews evenly and in sequence. Perform each step to all capscrews
before performing the next step.
Step 1 60 nm
Step 2 90 nm
Step 3 Turn all capscrews through 90 degrees.
The finish torque:176nm
The crankshaft must rotate freely after installing the main bearing caps.
Measure the crankshaft end play with a dial indicator assembly, Part Number and
magnetic base, Part Number Crankshaft End Play : mm

101 piston and connecting rod

Be sure FRONT and/or arrow marking on the top of the piston and the numbers on t
he connecting rod and cap are positioned at the right
Install the retaining ring in the pin groove on the front side of the piston.
Lubricate the pin and pin bores with clean 15W-40 engine lubricating oil.
Install the connecting rod.
Install the piston pin.
Install the second retaining ring.
Using piston ring expander, Part Number , install the rings on the piston.

102 piston and connecting rod assembly

Install the bearing shells into both the connecting rod and the connecting rod c
ap.
Lubricate the connecting rod bearings with a light film of assembly lubricant, P
art Number
Lubricate the rings and piston skirts with clean engine lubricating oil.
Position the rings so that the ring gaps are 120 degrees apart.
Lubricate the cylinder bore with clean 15W-40 lubricating engine oil.

103 piston and connecting rod assembly

Position the connecting rod journal for the piston to be installed to bottom dea
d center (BDC).
Align the front marking and/or arrow on the top of the piston so that it points to
wards the front of the engine.
Insert the connecting rod through the cylinder bore until the ring compressor co
ntacts the top of the cylinder block.
The long end of the connecting rod (1) will be on the exhaust side of the engine
. If not, verify the piston is installed correctly onto the connecting rod.

104 piston and connecting rod assembly

Hold the ring compressor against the cylinder block.
Push the piston through the ring compressor and into the cylinder bore.
Push the piston until the top ring is completely in the cylinder bore.
Carefully push the piston into the bore while guiding the connecting rod to the
crankshaft journal.
Use clean 15W-40 oil to lubricate the connecting rod capscrew threads and unders
ide of the connecting rod capscrew heads.

105 piston and connecting rod assembly

Install the connecting rod and capscrews
Use a marked socket and torque wrench to tighten the connecting rod capscrews.
The first step: 60nm
The second step :turn 60 clockwise
Finish torque :105+_20nm
Measure the side clearance between the connecting rod and crankshaft. Side Clear
ance Limits : mm
Check for freedom of rotation as the connecting rod caps are installed. If the c
rankshaft does not rotate freely, check the installation of the connecting rod b
earings and the bearing size.
106 Camshaft gear
Lubricate the camshaft nose with Lubriplate 105, or equivalent.
Install the camshaft gear locating key or dowel pin with a plastic mallet.
Heat the camshaft gear to 149C [300F] for 45 minutes.
Install the camshaft gear with the timing marks away from the camshaft.
Install the camshaft gear onto the nose of the camshaft. Align the camshaft gear
keyway with the camshaft locating key/dowel pin.

107 Camshaft gear

Using the camshaft gear removal and installation tool, Part Number Install the c
amshaft gear onto the nose of the camshaft. Align the camshaft gear keyway with
the camshaft locating key/dowel pin.
Use a mm [0.001 inch] feeler gauge to see if the feeler gauge can be inserted be
tween the camshaft gear and the shoulder on the camshaft. If the feeler gauge ca
n be inserted, the camshaft gear is not properly seated.

108 Camshaft
Apply assembly lubricant, Part Number , to the front camshaft bore.
Lubricate the camshaft lobes, journals, and thrust plate with assembly lubricant
, Part Number
Install the camshaft. While pushing in slightly, rotate the camshaft and careful
ly work the camshaft through the camshaft bushings. As each camshaft journal pas
ses through a bushing, the camshaft will drop slightly and the camshaft lobes wi
ll catch on the bushings. Rotating the camshaft will free the lobe from the bush
ing and allow the camshaft to be installed.

109 Camshaft
Before the camshaft gear engages the crankshaft gear, check the camshaft for eas
e of rotation. When installed properly, the camshaft must rotate freely.
Align the timing marks as illustrated and finish installing the camshaft.
Install the thrust plate.
Install the thrust plate capscrews. Torque Value: 24 nm
Use gauge, Part Number , and magnetic base, Part Number , to verify the camshaft
has proper backlash and end play. Camshaft End Play (A) mmCamshaft Gear Backlas
h Limits (B) : mm

110 Rotate pump

Verify cylinder Number 1 is at top dead center by barring the engine slowly whil
e pushing in on the top dead center pin.
Install a new gasket.
Install the pump. Make sure the key does not fall into the gear housing.
Hand tighten the three mounting nuts. The pump must be free to move in the slots
.
Install the pump drive shaft nut and spring washer. The pump will rotate slightl
y because of gear helix and clearance. Torque Value: 15 to 20 nm

111 Rotate pump

If installing the original pump, rotate the pump to align the scribe marks. Torq
ue Value: 24 nm
If installing a new or rebuilt pump without scribe marks, take up gear lash by r
otating the pump against the direction of drive rotation. Tighten the flange mou
nting nuts. Torque Value: 24 nm
Bosch VE
Loosen the Bosch fuel pump lock timing screw and install the special washer that
is wired to the fuel pump.
Tighten the Bosch fuel pump lock timing screw.
Torque Value: 13 nm

112 Rotate pump Disengage the timing pin before rotating the crankshaft.
Tighten the pump retaining nut.
Bosch VE (M nut): 98nm
Bosch VE (M12 nut): 65 nm
Install the access cap.

113 Line-in fuel pump top dead center. Remove the access plug.
Remove the timing pin. If the timing tooth is not aligned with the timing pin ho
le, rotate the fuel injection pump shaft until the timing tooth aligns.
Reverse the position of the timing pin so the slot of the timing pin will fit ov
er the timing tooth in the pump.
Install and secure the timing pin with the access plug.

114 Line-in fuel pump

Use clean lubricating engine oil 15w-40, to lubricate the gear cover housing to
make certain that the fuel injection pump will slide into the gear cover housing
easily.
Make certain that the o-ring seals for the fill orifice and pilot are correctly
installed and are not damaged.
Install new pilot o-ring.
Slide the pump shaft through the drive gear and position the pump flange onto th
e mounting studs.
Push the pump forward until the mounting flange and o-ring are properly fitted i
nto the gear housing bore.

115 Line-in fuel pump Install the mounting nuts. Torque Value: 43nm
Install the support bracket (if equipped). Torque Value: 32nm
Install the retaining nut and washer. Torque Value: 10 to 15nm To prevent damage
to the timing pins, do not exceed the torque value given. This is not the final
torque value for the retaining nut.
Disengage the engine timing pin.
Remove the access plug.

116 Line-in fuel pump

Add the following quantity of clean lubricating engine oil:
RSV 450 mL
RQV 750 mL
RQVK 750 mL
Remove the fuel injection pump timing pin plug, reverse the position of the timi
ng pin, and install the timing pin, plug, and sealing washer. Torque Value: 27 n
m
Tighten the fuel injection pump drive nut.
A Pump 85 nm
P3000 and P nm
Nippondenso nm
Install the gear cover access cap hand-tight.

117 Line-in fuel pump

Install the fuel injection pump mounting bracket capscrews.
Tighten all capscrews by hand for proper alignment. Torque Value: 24 nm
Connect the external oil feed line at the inboard side of the fuel injection pum
p (if applicable) and the main oil rifle.
Connect the external oil feed line at the rear of the pump or AFC latchout if ap
plicable.

118 Cylinder head assembly

Position a new cylinder head gasket over the dowels.
Carefully put the cylinder head straight down onto the cylinder block, and seat
it onto the dowels.
Position the push tubes into the valve tappets.
Lubricate the push tube sockets with clean lubricating engine oil.
Lubricate the valve stems with clean lubricating engine oil.
Completely loosen the rocker lever adjusting screws.
Install the pedestals.
Lubricate the 8-mm pedestal capscrew threads and under the capscrew heads with c
lean lubricating engine oil.
Install the capscrews finger-tight.

119 Cylinder head assembly

Lubricate the 12-mm pedestal/head capscrew bolt threads and under the capscrew h
eads with clean lubricating engine oil.
Install the capscrews finger tight.
Lubricate the threads and under the heads on the remaining cylinder head capscre
ws with clean lubricating engine oil.
Install capscrews in the cylinder head and finger-tighten.
On a four cylinder engine, capscrew number 1 is located in between cylinders 2 a
nd 3. The numbered sequence is the same as a six cylinder, but stops at capscrew
number 18. Follow the numbered sequence for the four cylinder engine, and tight
en all 18 capscrews.
Torque Value: 90nm

120 Cylinder head assembly

Follow the numbered sequence for the six cylinder engine, and tighten all 26 cap
screws.
Torque value:90nm
Four Cylinder
Follow the numbered sequence, and tighten the long capscrews only (numbers 4,5,1
2, and 13).
Six Cylinder
Follow the numbered sequence, and tighten the long capscrews only (numbers 4, 5,
12, and 13, 20, and 21).
Torque Value: 120 nm