Part 2
Engine
4.0L SOHC Engine - Upper Components
4.0L SOHC Engine - Front and Rear Components
4.0L SOHC Engine - Lower Components
NOTICE: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail.
NOTE: During engine assembly it may be necessary to check the bearing clearances and crankshaft end play. For additional information, refer to Engine.
NOTE: Before engine assembly, use silicone gasket remover and metal surface prep and a suitable plastic or wooden scraper to clean the sealing surfaces. Follow the directions on the packaging. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.
45. NOTICE: The cylinder block cradle inserts must be loosened completely or damage to the cylinder block cradle or oil leaks can result.
Loosen the 8 cylinder block cradle inserts.
46. 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 in the 6 places shown.
47. Position the cylinder block cradle and a new gasket assembly.
48. Install and finger-tighten the 20 bolts and 2 nuts.
49. Install and finger-tighten the 2 Torx bolts.
50. NOTE: The cylinder block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle underflush or 0.05 mm (0.00196 in) cylinder block cradle protrusion.
Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.
51. Tighten the 20 bolts and the 2 nuts.
- Tighten the nuts to 10 Nm (89 lb-in).
- Tighten the bolts to 14 Nm (124 lb-in).
52. Tighten the Torx bolts.
- Tighten to 10 Nm (89 lb-in).
53. Tighten the 8 inserts.
- Tighten to 3 Nm (27 lb-in).
54. Install new seals on the 2 silver bolts and position them in the cylinder block cradle.
55. Position the 6 remaining bolts.
56. Tighten the 8 cylinder block cradle inner bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten to 34 Nm (25 lb-ft).
57. NOTE: The cylinder block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle underflush or 0.05 mm (0.00196 in) cylinder block cradle protrusion.
Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.
- Cradles that exceed protrusion specification must be removed and the appropriate assembly steps repeated.
- Cradles that exceed the underflush specification may be repaired by installing shims (next step).
58. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the cylinder block cradle.
59. Install the oil pump screen cover and tube and the bolt.
- Tighten to 10 Nm (89 lb-in).
60. Install the gasket, the oil pan and the 10 bolts.
- Tighten to 11 Nm (97 lb-in).
61. Inspect and install new oil filter adapter O-ring seals if necessary.
62. Install the oil filter adapter and the bolt.
- Tighten to 57 Nm (42 lb-ft).
63. Install a new gasket, the coolant pump and the 13 bolts.
- Tighten to 10 Nm (89 lb-in).
64. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
65. NOTE: A new bolt must be used each time it is removed.
Using the Strap Wrench, tighten the bolt in 2 stages.
- Stage 1: Tighten to 55 Nm (41 lb-ft).
- Stage 2: Rotate an additional 85 degrees.
66. Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
67. Position the Crankshaft Position (CKP) sensor and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
68. NOTE: LH shown, RH similar.
Install the cylinder head gaskets.
69. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Install the RH cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 12 Nm (106 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
70. Install 2 new 8-mm bolts.
- Tighten to 32 Nm (24 lb-ft).
71. Tighten the 8 new 12-mm bolts in the sequence shown in 2 stages.
- Stage 1: Rotate 90 degrees.
- Stage 2: Rotate an additional 90 degrees.
72. Position the RH camshaft sprocket.
73. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.
NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt.
Loosely install the RH camshaft sprocket bolt.
74. Install the RH cassette-to-cylinder head bolt.
- Tighten to 10 Nm (89 lb-in).
75. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Install the LH cylinder head and tighten the 8 new 12-mm bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 12 Nm (106 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
76. Install 2 new 8-mm bolts.
- Tighten to 32 Nm (24 lb-ft).
77. Tighten the 8 new 12-mm bolts in the sequence shown in 2 stages.
- Stage 1: Rotate 90 degrees.
- Stage 2: Rotate an additional 90 degrees.
78. Position the LH camshaft sprocket.
79. NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt.
Loosely install the LH camshaft sprocket bolt.
80. Install the LH cassette-to-cylinder head bolt.
- Tighten to 12 Nm (106 lb-in).
81. Turn the crankshaft one revolution clockwise.
82. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.
NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block. This positions the engine at Top Dead Center (TDC).
Install the Crankshaft TDC Timing Tool.
83. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft.
Install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the RH cylinder head.
84. NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the rear of the RH cylinder head.
85. Install the Timing Chain Tensioner.
86. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.
Tighten the bolts.
1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).
87. Install a new washer and the RH timing chain tensioner.
- Tighten to 44 Nm (32 lb-ft).
88. NOTE: Do not tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts. The camshaft sprocket must rotate freely.
Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH cylinder head.