Part 2
Engine
Engine - Upper End
Engine - Front End
Engine - Lower End
Assembly
51. 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 the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
52. 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.
53. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
54. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
55. Remove the retaining clips from the RH and LH timing chain tensioners.
56. Check for correct alignment of all timing marks.
57. Install the crankshaft sensor ring on the crankshaft.
58. NOTICE: Only use hand tools to tighten the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
Tighten the RH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
59. NOTICE: Only use hand tools to tighten the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
Tighten the LH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
60. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
61. Remove the 2 bolts and the middle balance shaft bearing support and camshaft bearing cap assembly.
62. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the Valve Spring Compressor, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.
63. Position the camshaft bearing cap and install the 2 bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
64. Remove the 2 bolts and the rear balance shaft bearing support and camshaft bearing cap assembly.
65. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the Valve Spring Compressor, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.
66. Position the camshaft bearing cap and install the 2 bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
67. NOTICE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
Using the Valve Spring Compressor, install all of the remaining camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.
68. Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
69. Lubricate the balance shaft journals with clean engine oil.
70. NOTE: Camshaft sprocket removed from art for clarity.
Position the balance shaft on the journals and align the timing mark on the balance shaft with the camshaft timing mark as shown.
71. NOTICE: The balance shaft bearing caps must be installed into their original locations or engine damage may occur.
Install the 6 bolts and tighten in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
72. NOTICE: 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may 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.
73. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.
74. Tighten the 15 engine front cover fasteners in sequence in 3 stages.
Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
Stage 3: Tighten fasteners 8 through 15 to 25 Nm (18 lb-ft).
75. NOTICE: 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.
76. Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).
77. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
78. Using the Crankshaft Vibration Damper Installer, Front Cover Seal Installer and Crankshaft Front Oil Seal Installer, install a new crankshaft front seal.
79. 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
80. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
81. Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
82. Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
83. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).
84. NOTE: LH shown, RH similar.
If equipped, install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).
85. NOTICE: 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 the bolts to 25 Nm (18 lb-ft).
- Tighten the nut to 48 Nm (35 lb-ft).
86. NOTE: RH shown, LH similar.
Install 20 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
87. Position 2 new gaskets, the LH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Exhaust Manifold - LH:
88. Position the exhaust manifold heat shield and install the 3 bolts.
- Tighten to 14 Nm (124 lb-in).
89. NOTICE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
NOTICE: Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator damage.
NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.
Position the engine support insulator bracket and install 3 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional minimum of 60 degrees.
90. Position 2 new gaskets, the RH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Exhaust Manifold - RH:
