Installation

INSTALLATION





NOTE: Make sure that all sealing surfaces on the engine are clean and free of oil.

1. Make sure the front cover o-rings at the water pump inlet and outlet are intact and in place.
2. Turn the balance shaft so that the timing mark on the balance shaft matches the timing mark on the engine block.
3. Make sure the timing chain is correctly mounted to the crankshaft and balance shaft sprockets.
4. Install the front cover.
5. Install the front cover bolts. Use a cross pattern to tighten the front cover bolts to 20 Nm ( 177 in. lbs.).




6. Install the cylinder head to front cover bolts (1) in the right cylinder head.
7. Tighten the cylinder head to front cover bolts to 15 Nm (132 in. lbs.) and then an additional 90 degrees.




8. Install the cylinder head to front cover bolts (1) in the left cylinder head.Tighten the cylinder head to front cover bolts to 15 Nm (132 in. lbs.) and then an additional 90 degrees.




9. Coat the end of the camshafts (1) with a small amount of oil.
10. Line up the pin in the camshaft adjusters (4) with the hole in the camshafts (2).




11. The camshaft pulse wheel must be replaced every time it is removed. The dimples in the pules wheel must line up with the depressions in the camshaft adjusters.




12. Make sure that the crankshaft is set to 40° ATDC, and that the crankshaft lock is installed.
13. When the crankshaft adjusters are correctly installed, the timing marks (4) will line up with each other and the top mark (3) will be pointed up.
14. Install the timing chain onto the left cylinder head intake camshaft adjuster.
15. Install the camshaft adjuster to the intake camshaft in the left cylinder head.
16. Install the camshaft adjuster to the exhaust camshaft in the left cylinder head. Make sure the timing marks line up correctly.




17. Install the slide rails (3).
18. Install the timing chain on the right cylinder head intake camshaft adjuster.
19. Install the right cylinder head camshaft adjuster to the intake camshaft.
20. Install the right cylinder head exhaust camshaft adjuster.
21. Verify that the intake camshafts are correctly timed to the crankshaft position.

NOTE: The center valves in the exhaust camshafts are L. H. thread. The center valves in the intake camshafts are R.H. thread.

22. Install new CMP plates.
23. Install the center valves into the left (1) and right (4) cylinder head camshafts.
24. Tighten the camshaft adjuster center valves to 145 Nm (106 ft. lbs.).




25. Remove the drift (3) from the camshafts.




26. Reset the timing chain tensioner by removing the end (1) of the tensioner assembly.
27. Remove the sealing ring from the tensioner assembly (2).
28. Remove the spring (3) and (4) pin from the tensioner assembly.
29. Replace the pin (8) into the back of the tensioner assembly, followed by the spring (3), dowel (4), sealing ring (2), and tensioner end (1).
30. Tighten the end of the tensioner (1) to 50 Nm (36 ft. lbs.)
31. Install the timing chain tensioner and tighten to 70 Nm (51 ft. lbs.)




32. Apply silicone to the cylinder head cover sealing surface.
33. Install the right cylinder head cover.
34. Install the left cylinder head cover.
35. Use the illustrated pattern to tighten the cylinder head cover bolts to 12 Nm (106 in. lbs.) and then an additional 90 degrees.




36. Install the power steering pump.Power Steering Pump - Installation
37. Install the AC compressor.A/C Compressor - Installation
38. Install the left air control valve adapter gasket.




39. Install the left air control valve adapter. Tighten the left air control valve adapter bolts to 14 Nm (143 in. lbs.)
40. Install the left air control valve gasket.




41. Install the left air control valve. Tighten the left air control valve bolts to 14 Nm (143 in. lbs.)




42. Apply a bead of silicone to the cylinder head front cover sealing surface.
43. Install the left front cylinder head cover (1).
44. Tighten the front cover bolts in a cross pattern to 8 Nm (70 in. lbs).




45. Apply a bead of silicone to the cylinder head front cover sealing surface.
46. Install the upper right front cylinder head cover (1).
47. Tighten the front cover bolts in a cross pattern to 8 Nm (70 in. lbs).




48. Install the right air control valve gasket.




49. Install the right side air control valve.
50. Install the right air control valve bolts.
51. Tighten the bolts to 14 Nm (123 in. lbs).




52. Install the water pump gasket.




53. Install the water pump.
54. Tighten the water pump bolts in a cross pattern to 25 Nm (221 in. lbs.).




55. Install the water pump pulley (6).
56. Install the water pump pulley bolts (5).
57. Tighten the water pump pulley M7 bolts to 10 Nm (88 in. lbs.) and then to 25 Nm (221 in. lbs.).
58. Tighten the water pump pulley M8 bolts to 5 Nm (44 in. lbs.) and then to 20 Nm (220 in. lbs.).
59. Install the crankshaft damper pulley (3).
60. Install the crankshaft damper bolt (4) and tighten to 200 Nm (147 ft. lbs.) and then an additional 90 degrees.
61. Install the idler pulley (1).
62. Tighten the idler pulley bolts to 35 Nm (26 ft. lbs.)




63. Install the oil filter/cooler housing (2).
64. Use the illustrated pattern to tighten the oil filter/cooler housing (2) bolts to 20 Nm (15 ft. lbs.).




65. Install the thermostat gasket.




66. Install the thermostat housing and tighten the bolts to 25 Nm (220 in. lbs).




67. Install the accessory drive belt tensioner assembly and tighten the bolts to 35 Nm (25 ft. lbs.).
68. Install the accessory drive belt.




69. Install the air pump (5).
70. Install the intake manifold.Intake Manifold - Installation




71. Install the engine harness.
72. Install the PCM.




73. Raise the vehicle.
74. Remove the crankshaft lock.
75. Install the starter.Starter Motor - Installation




76. Install the generator.Generator - Installation




77. Install the upper oil pan.Engine Oil Pan - Installation




78. Install the lower oil pan.Engine Oil Pan - Installation




79. Install the oil dipstick and oil dipstick tube.
80. Install the lower bolt to the engine oil dipstick tube.
81. Install the upper oil dipstick tube bolt and tighten to 9 Nm (80 in. lbs).




82. Install the lower splash shield.
83. Lower the vehicle.
84. Connect the remote battery ground.
85. Fill the coolant.Service and Repair
86. Fill the engine oil.Maintenance




87. Install the cooling module.




88. Install the grille (1).




89. Install the engine cover.
90. Close the hood.