Part 2
Cylinder HeadsInstallation (Steps 37-72)
37. Install the RH timing chain tensioner arm.
^ Tighten to 11 Nm (8 ft. lbs.).
38. Install the RH timing chain tensioner. Install the timing chain tensioner and bolts, and remove the drill rod.
39. 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 2 stages.
^ Stage 1: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
40. Remove the special tool.
41. Remove the special tool.
42. NOTE: Lubricate the VCT bush carrier seals with clean engine oil.
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 the bolts and nut.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).
^ Tighten the nut to 10 Nm (89 inch lbs.).
43. Install new engine front cover gaskets.
44. NOTE: if the front cover is not secured within 4 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 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in the 8 places shown.
45. Install the engine front cover.
^ Position the engine front cover on the cylinder block.
^ Loosely install the bolts.
^ Tighten the bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 inch lbs.).
- Stage 2: Tighten to 10 Nm (89 inch lbs.).
46. NOTE: Lubricate the front oil seal and the engine front cover mating surface with clean engine oil.
Using the special tool, install a new front crankshaft seal.
47. NOTE: If the crankshaft pulley is not secured within 4 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 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant to the keyway.
48. Using the special tool, install the crankshaft pulley.
49. Install a new bolt and using the special tool to hold the pulley, tighten in 4 stages.
^ Stage 1: Tighten to 80 Nm (59 ft. lbs.).
^ Stage 2: Loosen the bolt 2 complete turns.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
LH side
50. Install the 8 new LH exhaust manifold studs.
^ Tighten to 19 Nm (14 ft. lbs.).
51. Install the new LH exhaust manifold gasket and the heat shield stud bolt.
^ Tighten to 50 Nm (37 ft. lbs.).
52. Install the LH exhaust manifold and the 8 new nuts.
^ Tighten the nuts to 25 Nm (18 ft. lbs.) in the sequence shown.
53. Install the LH exhaust manifold heat shield and 4 bolts.
^ Tighten to 3 Nm (27 inch lbs.).
RH side
54. Install the 8 new RH exhaust manifold studs.
^ Tighten to 19 Nm (14 ft. lbs.).
55. Install the new RH exhaust manifold gasket and the heat shield stud bolt.
^ Tighten to 50 Nm (37 ft. lbs.).
56. Install the RH exhaust manifold and the 8 new nuts.
^ Tighten the nuts to 25 Nm (18 ft. lbs.) in the sequence shown.
57. Install the RH exhaust manifold heat shield and 4 bolts.
^ Tighten to 3 Nm (27 inch lbs.).
58. Install a new gasket, EGR tube and 2 nuts.
^ Tighten to 20 Nm (15 ft. lbs.).
Both sides
59. NOTE: RH shown, LH similar.
Install new valve cover gaskets.
60. NOTE: RH shown, LH similar.
NOTE: If the valve covers are not secured within 4 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 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply 4 beads of silicone gasket and sealant as shown.
61. Install the LH valve cover.
^ Tighten the bolts in the sequence shown to 10 Nm (89 inch lbs.).
62. Install the RH valve cover.
^ Tighten the bolts in the sequence shown to 10 Nm (89 inch lbs.).
63. Install new intake manifold gaskets.
64. Install the intake manifold, the 7 bolts and the 3 studs.
^ Tighten the 7 bolts and the 3 studs in the sequence shown to 20 Nm (15 ft. lbs.).
65. Install a new gasket, the throttle body adapter and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
66. Install new O-ring seals, the coolant bypass housing and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
67. Connect the 2 throttle body coolant hoses.
68. NOTE: RH shown, LH similar.
Install the 2 radio interference ignition capacitors and the 2 nuts.
^ Tighten to 10 Nm (89 inch lbs.).
69. Connect the exhaust manifold tube to the exhaust gas recirculation (EGR) system module.
^ Tighten to 40 Nm (30 ft. lbs.).
70. Install the crankcase vent tube.
71. Install the 8 ignition coils and bolts.
^ Tighten to 5 Nm (44 inch lbs.).
72. CAUTION: Failure to lubricate the O-ring seal and the oil level indicator tube-to-engine block mating surface with clean engine oil can result in engine oil leaks.
CAUTION: Make sure the O-ring seal remains in position and does not roll up the indicator tube during installation.
Install a new O-ring seal, oil level indicator tube and nut.
^ Lubricate the new O-ring seal and engine mating surface with clean engine oil.
^ Tighten to 6 Nm (53 inch lbs.).