Part 2 of 3

Engine Continued





40. NOTE: RH shown, LH similar.

Install the camshaft sprockets and camshaft sprocket bolts finger tight.





41. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Compress the tensioner plunger, using a vise.





42. Install a retaining clip on the tensioner to hold the plunger in during installation.





43. NOTE: There are 61 links in each timing chain.

If copper links are not visible, mark 2 links on one end and one link on the other end, and use as timing marks.





44. Install the timing chain guides and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).





45. Preposition the camshafts.
1. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.
2. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.





46. Install the crankshaft sprocket, marking sure the flange faces forward.





47. Install the lower end of the LH timing chain, aligning the timing marks.





48. NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.

Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.





49. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





50. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

NOTE: The lower half of the timing chain must be positioned above the dowel.

Install the RH (outer) timing chain on the crankshaft sprocket.





51. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.





52. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





53. Remove the retaining clips from the RH and LH timing chain tensioners.





54. Check for correct alignment of all timing marks.





55. Install the crankshaft sensor ring on the crankshaft.
56. Lubricate the balance shaft journals with clean engine oil.





57. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
58. Position the balance shaft on the journals.





59. NOTE: It may be necessary to use an inspection mirror to see the marks.

Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.





60. NOTE: Install the balance shaft bearing caps in their original locations.

Install the bolts and tighten in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).





61. CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.

Tighten the RH camshaft sprocket bolt in 2 stages:
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.) in the sequence shown.
^ Stage 2: Tighten an additional 90 degrees.





62. CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.

Tighten the LH camshaft sprocket bolt in 2 stages:
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.) in the sequence shown.
^ Stage 2: Tighten an additional 90 degrees.





63. CAUTION: If the components are to be reinstalled, they must be installed into their original locations.

Using the special tool, install all of the remaining camshaft roller followers.
^ Lubricate the roller followers with clean engine oil prior to installation.





64. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.





65. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.











66. Tighten the engine front cover fasteners in sequence in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 ft. lbs.).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.).





67. Install the 4 front oil pan bolts in the sequence shown, in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 60 degrees.





68. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





69. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Position the coolant pump and install the bolts loosely.
^ Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.





70. Tighten the 4 coolant pump bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





71. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.





72. Using the special tools, install the crankshaft seal into the engine front cover.





73. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





74. Use the special tool to install the crankshaft pulley.





75. Tighten the new crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.





76. Position the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





77. Position the accessory drive belt tensioner and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





78. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





79. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: Clean and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts and the nut.
^ Tighten to 25 Nm (18 ft. lbs.).