Part 2

Engine

Assembly (Steps 57-82)

NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

57. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.





58. Using a small pick, push back and hold the ratchet mechanism.





59. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





60. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.





61. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
^ Tighten to 10 Nm (89 inch lbs.)





62. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
^ Tighten to 72 Nm (53 ft. lbs.)





63. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the mounting surfaces of the engine and the front cover.

64. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.

Apply a 2.5 mm (0.09 inch) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 inch) bead of silicone gasket and sealant to the front cover





65. Install the engine front cover. Tighten the bolts in the sequence shown, to these specifications:
^ Tighten the 8-mm bolts to 10 Nm (89 inch lbs.)
^ Tighten the 13-mm bolts to 48 Nm (35 ft. lbs.)





66. NOTE: Remove the through-bolt from the special tool.

NOTE: Lubricate the oil seal with clean engine oil.

Using the special tool, install the crankshaft front oil seal.





67. CAUTION: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.





68. CAUTION: Only hand-tighten the 6 mm (0.23 inch) bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install a standard 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover.






69. CAUTION: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.

CAUTION: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
^ Stage 1: Tighten to 100 Nm (74 ft. lbs.)
^ Stage 2: Tighten an additional 90° (1/4 turn.)





70. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





71. Remove the special tool.





72. Remove the special tool.





73. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise 1 and 3/4 turns.

74. Install the special tool.





75. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise until the crankshaft contacts the special tool.





76. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt, check the position of the crankshaft pulley.
^ If it is not possible to install the bolt, the engine valve timing must be corrected.





77. Install the special tool to check the position of the camshafts.
^ If it is not possible to install the special tool, the engine valve timing must be corrected.





78. Remove the special tool.





79. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.

Install a new CKP sensor and the 2 bolts.
^ Do not tighten the bolts at this time.





80. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.

Adjust the CKP sensor with the alignment tool.
^ Tighten the 2 CKP bolts to 7 Nm (62 inch lbs.)





81. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





82. Remove the special tool.