Part 2
Engine - Assembly - (Con't.)35. Remove the special tool.
36. Install the crankshaft sprocket and lower end of the LH (inner) timing chain, aligning the timing marks.
37. NOTE: Make sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, use the Camshaft Position Tool to adjust.
NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment. Specifications
Position the-timing chain on the camshaft sprocket with the two copper chain links and the camshaft sprocket timing mark aligned.
38. CAUTION: The camshaft sprocket can jump time if the Camshaft Position Tool is not secured.
NOTE: Be sure the copper chain link and crankshaft sprocket timing mark are aligned.
NOTE: The lower half of the timing chain must be positioned above the dowel.
Position the RH (outer) timing chain on the camshaft sprocket.
39. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark.
40. As a post-check, verify timing mark alignment.
41. NOTE: The LH timing chain tensioner arm has a bump near the dowel hose, for identification.
Position the LH and RH timing chain tensioner arm on the dowel pins. Position the timing chain tensioners, and install the bolts.
42. Remove both the RH and LH retaining clips from the timing chain tensioners.
43. Remove the special tools from the camshafts.
44. Lubricate the balance shaft journals with clean engine oil.
45. Using the index mark on the balance shaft, mark the corresponding teeth on the gear with chalk.
46. Position the balance shaft on the journals.
47. Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
48. Install the bearing caps in their original locations and the bolts. Tighten the bolts in the sequence shown.
49. Position the crankshaft sensor ring.
50. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
NOTE: The RH timing chain is removed for clarity.
Apply a bead of silicone gasket and sealant along the cylinder head-to-block surface and the oil pan-to-cylinder block surface as specified.
51. Install a new engine front cover gasket onto the engine front cover, then position the engine front cover on the front cover to cylinder block dowel.
Engine Front Cover Bolt Sequence:
52. Loosely install the fasteners.
53. Tighten the fasteners in two stages.
^ Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 ft. lbs.).
54. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil.
Install the oil pump screen and pickup tube.
1 Install and tighten the spacer.
2 Insert the oil pump screen pickup tube into the oil pump and position the support bracket over the spacer.
3 Install and tighten the bolts.
55. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant where the rear crankshaft seal retainer plate and the front cover meets the cylinder block.
56. NOTE: Be sure to tighten the bolts in three stages.
Install the oil pan. Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 60°.
57. Install the oil drain plug.
58. CAUTION: Do not rotate the water pump housing once the water pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
Install the water pump.
1 Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the water pump.
2 Position the water pump into the cylinder block.
^ Install the water pump retaining bolts.
59. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
60. Use the special tool to install the crankshaft front seal into the engine front cover.
61. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
62. Use the special tool to install the crankshaft pulley.
63. Tighten the crankshaft pulley bolt in four stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360°.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 85 - 95°.
64. Position the water pump pulley on the water pump and install the bolts.
65. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
66. Position the valve covers.
67. Tighten the bolts in the sequence shown.
68. Install the engine control wire harness.