Part 2 of 2

Items 24-51: Timing Drive Components Installation Note





1. Reset the timing chain tensioners.
1 Hold the lever toward the tensioner piston.
2 Using finger pressure, compress the tensioner.
3 Push the lever down and install a drill rod to lock the piston.





2. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the LH head.





3. Position the LH timing chain and crankshaft gear.
^ Position the timing chain over the LH intake camshaft sprocket.
^ Position the crankshaft gear in the timing chain.





4. Install the LH timing chain guide.





5. Install the LH timing chain tensioner arm.





6. Install the LH timing chain tensioner.
1 Install the timing chain tensioner and bolts.
2 Remove the drill rod.





7. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.

CAUTION: Using the special tool, apply 10 Nm(89 inch lbs.) counterclockwise to the LH exhaust camshaft sprocket.

Tighten the LH exhaust camshaft sprocket and Variable Camshaft Timing (VCT) unit bolts in two stages:
^ Stage 1: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





8. Remove the special tool.





9. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.

Install the special tool on the right cylinder head.





10. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.





11. Install the RH timing chain guide.





12. Install the RH timing chain tensioner arm.





13. Install the RH timing chain tensioner.
1 Install the timing chain tensioner and bolts.
2 Remove the drill rod.





14. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.

CAUTION: Using the special tool, apply 10 Nm (89 inch lbs.) counterclockwise to the RH exhaust camshaft sprocket.

Tighten the RH exhaust camshaft sprocket and VCT unit bolts in two stages:
^ Stage 1: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





15. Remove the special tool.





16. Remove the special tool.





17. Install the Crankshaft Position (CKP) sensor.

Items 52 and 55: Variable Cam Timing (VCT) Bush Carrier Installation Note
1. Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting bolts.

Items 58 and 59: Engine Front Cover Installation Note





1. NOTE: If the front cover is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in eight places.





2. Install the engine front cover.
^ Install new gaskets.
^ Position the engine front cover on the cylinder block.
^ Loosely install the bolts.
^ Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 inch lbs.).
- Stage 2: Tighten to l0 Nm (89 inch lbs.).

Items 61-62 and 67-68: Exhaust Manifold Installation Note





1. NOTE: RH is shown, LH is similar.

Install the exhaust manifold.
^ Install a new gasket and the exhaust manifold.
^ Tighten the eight nuts in the sequence shown.

Item 67: RH Exhaust Manifold Installation Note





1. Install the EGR tube.
^ Install a new EGR tube gasket.
^ Install the EGR tube.
^ Install the EGR tube nuts.

Items 72-79: RH and LH Valve Cover Installation Note





1. NOTE: RH is shown, LH is similar.

Inspect and install new gaskets as necessary.





2. NOTE: RH is shown, LH is similar.

NOTE: If the valve covers are not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply four beads of silicone gasket and sealant as shown.





3. NOTE: RH is shown, LH is similar.

Install the valve covers.
^ Tighten the bolts in the sequence shown.

Items 81-83: Intake Manifold Installation Note





1. Install new intake manifold gaskets.





2. Install the intake manifold and tighten the bolts in the sequence shown.





3. NOTE: RH is shown, LH is similar.

Install the radio interference capacitor and the nut.

Item 96: EGR System Module Installation Note





1. Connect the EGR system module-to-exhaust manifold tube from the EGR system module.

Item 103: Engine Wiring Harness Installation Note





1. Install the wiring harness onto the front cover.





2. Install the wiring harness onto the front cover.





3. Connect the Crankshaft Position (CKP) sensor electrical connector.





4. Install the exhaust gas Oxygen Sensor (H02S) connectors onto the brackets.





5. NOTE: LH shown, RH similar.

Connect the two pin-type retainers.





6. NOTE: RH is shown, LH is similar.

Connect the Variable Cam Timing (VCT) sensor electrical connector.





7. Install the engine wiring harness retainer.





8. NOTE: LH is shown, RH is similar.

Connect the fuel injector and radio interference capacitor electrical connectors.





9. NOTE: LH shown, RH similar.

Connect the ignition coil electrical connectors.
10. Connect the EGR system module electrical connector.





11. Connect the generator electrical connector.





12. NOTE: LH is shown, RH is similar.

Connect the engine wiring harness retainers to the RH engine appearance cover support bracket.

Items 106 and 107: Engine Cover Support Bracket Installation Note





1. Install the engine wiring harness retainers onto the engine cover support bracket.

Items 122-125: RH and LH Coil Cover Installation Note





1. NOTE: Remove all dirt and moisture from the valve cover before applying silicone sealer.

Lift up the wire harness and apply a 12.7 mm (0.5 inch) bead of silicone sealer in the notch of the valve cover.





2. Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.





3. Install the coil cover.





4. Connect the wiring harness retainers to the RH valve cover.





5. Connect the wiring harness retainers to the RH valve cover.

Item 129: Front Crankshaft Seal Installation Note





1. NOTE: Lubricate the front oil seal and the engine front cover mating surface with clean engine oil.

Using the special tool, install the front crankshaft seal.

Items 130-132: Crankshaft Pulley Installation Note





1. NOTE: If the crankshaft pulley is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the crankshaft pulley keyway.





2. Using the special tool, install the crankshaft pulley.





3. NOTE: Use strap wrench (303-D055) while tightening crankshaft pulley bolt.

Install the washer and a new bolt and tighten hi two stages.
^ Stage 1: Tighten to 80 Nm (59 ft. lbs.).
^ Stage 2: Tighten an additional 80 degrees.

Item 134: Coolant Pump Pulley Bolt Installation Note
1. Do not tighten coolant pump pulley bolts until after the accessory drive belt has been installed.

Items 144 and 145: Oil Filter and Seal Installation Note
1. Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.