Part 2

Engine

34 Install the LH variable camshaft timing (VCT) oil control unit.
- Install the new O-ring seals.
- Tighten the new bolts to 22 Nm.
- Tighten the nut to 10 Nm.





35 Install the RH primary timing chain.
- Make sure the timing chain slack is on the tensioner side of the timing chain.





36 Install the RH primary timing chain tensioner guide.
- Tighten the bolts to 12 Nm.





37
CAUTION: During timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
Install the RH primary timing chain tensioner.
- Using 3 mm diameter metal rod, retain the chain tensioner piston.
- Tighten the bolts to 12 Nm.
- Remove the retaining rod.





38
CAUTION: Using the special tool, apply force to the tool in a counter-clockwise direction, to tension the primary timing chain on its drive side.
CAUTION: The intake camshaft sprocket retaining bolt MUST be tightened before the exhaust camshaft sprocket retaining bolt. Engine damage will occur if this procedure is not followed.
CAUTION: Make sure that new bolts are installed.
Install the special tool to the exhaust camshaft sprocket.
- Tighten the intake camshaft sprocket bolt to 20 Nm then a further 90 degrees.
- Tighten the exhaust camshaft sprocket bolt to 20 Nm then a further 90 degrees.





39 Install the RH VCT oil control unit.
- Install the new O-ring seals.
- Tighten the new bolts to 22 Nm.





40 Remove the special tool from the LH cylinder head.





41 Remove the special tool from the RH cylinder head.





42 Remove the crankshaft locking tool.
- Remove the screw.





43 Install the engine front cover.
- Clean the component mating faces.
- Apply a bead of sealant 3 mm diameter, by 12 mm long, to the 8 places indicated.





44 Evenly and progressively tighten the bolts in the sequence shown to 12 Nm.





45 Using the special tools, install the crankshaft front seal.
- Clean the component mating faces.
- Lubricate the seal with clean engine oil.
- Use the discarded crankshaft bolt with the service tool.





46 Using the special tools, install the crankshaft front seal.
- Clean the component mating faces.

47 Install the crankshaft pulley.
- Lubricate the seal with clean engine oil.

48 Install the crankshaft pulley locking ring.

49
CAUTION: The screw thread in the crankshaft pulley must be cleaned out before installing a new crankshaft pulley bolt.
Install, but do not tighten, the new crankshaft pulley bolt.





50
CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft.
Using the special tools, retain the crankshaft pulley.
- Tighten the crankshaft pulley bolt to 380 Nm.

51 Remove the special tools.





52 Install new valve cover plug aperture gaskets.
- Install a new valve cover gasket.





53
NOTE:
Apply two beads of silicone gasket sealant as shown on the illustration. The application of the sealant must be 3mm diameter 12mm long. Install the valve cover immediately after applying the sealant. The cover should be fitted directly to the head without smearing the sealant or the seals.
Install the valve cover.
- Clean the component mating faces.





54 Install the valve cover retaining bolts.
- Install valve cover retaining bolts to their position previously noted.
- Complete the tightening sequence as illustrated.
- Tighten the bolts to 12 Nm.





55 Install new valve cover plug aperture gaskets.
- Install a new valve cover gasket.





56
NOTE:
Apply two beads of silicone gasket sealant as shown on the illustration. The application of the sealant must be 3mm diameter 12mm long. Install the valve cover immediately after applying the sealant. The cover should be fitted directly to the head without smearing the sealant or the seals.
Install the valve cover.
- Clean the component mating faces.





57 Install the valve cover retaining bolts.
- Install valve cover retaining bolts to their position previously noted.
- Tighten the bolts to 12 Nm.
- Complete the tightening sequence as illustrated.





58 Install the 8 ignition coil-on-plugs.
- Install the 8 bolts.
- Tighten the bolts to 6 Nm.





59 Install the generator mounting bracket.
- Clean the locating dowels.
- Clean the component mating faces.
- Tighten the bolts to 45 Nm.





60 Install the A/C mounting bracket.





61 Install the coolant manifold.
- Tighten the bolts to 6 Nm.





62 Install the coolant pump pulley.
- Tighten the bolts to 10 Nm.





63 Install the accessory drive belt idler pulley.
- Tighten the bolt to 25 Nm.





64 With assistance, install the intake manifold.
- Install the gaskets.
- Evenly and progressively tighten the bolts to 20 Nm.





65 Install the purge valve.
- Secure the electrical harness with the clip.
- Tighten the bolt to 6 Nm.
- Connect and secure the electrical connector.





66 Connect the starter motor positive cable.
- Secure the cover.





67 Connect the oil temperature and oil pressure sensors.





68 Install the generator.
- Clean the component mating faces.
- Tighten the bolts to 48 Nm.
- Connect the generator electrical connector.
- Secure the clips.





69 Install the crankshaft position (CKP) sensor electrical connector.
- Connect the CKP sensor electrical connector.





70 Install the power steering pump mounting bracket.
- Clean the component mating faces.
- Tighten the bolts to 25 Nm.
- Secure the transmission cooler pipes into clips.





71 Connect and secure the CMP sensor electrical connectors.
- Repeat the operation for the RH side.





72
NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
Connect the KS electrical connector.





73 Connect the engine coolant temperature (ECT) sensor electrical connector.





74 Connect the ignition coil-on-plug electrical connections.
- Install the clips.
- Repeat the above procedure for the other side.





75 Connect the VCT oil solenoid electrical connector.
- Repeat the above procedure for the other side.
- Connect the valve cover breather hose.





76 Connect the cylinder head earth ground connector.
- Install the bolt.
- Secure the 3 clips.





77 Install the ignition coil-on-plug cover.
- Secure the clips.
- Repeat the above procedure for the other side.

78 Remove the engine from the engine stand.

79 Install the engine assembly.