Part 2
EngineAssembly (Steps 41-80)
Engines with ratcheting timing chain tensioners
41. Remove the retaining clip from the LH timing chain tensioner.
Engines with non-ratcheting timing chain tensioners
42. Remove the retaining clip from the LH timing chain tensioner.
All engines
43. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
44. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
45. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
Engines with ratcheting timing chain tensioners
46. Remove the retaining clip from the RH timing chain tensioner.
Engines with non-ratcheting timing chain tensioners
47. Remove the retaining clip from the RH timing chain tensioner.
All engines
48. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
49. Rotate and camshaft until the lobe is in the up position.
50. Install the special tool between the valve spring coil to prevent valve stem seal damage.
51. NOTE: Lubricate the camshaft roller followers using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
Install the 16 camshaft roller followers.
1 Install the special tool.
2 Compress the valve spring.
3 Install the 16 camshaft roller followers in their original locations.
52. Remove the special tool.
53. Install all 8 spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).
54. Install the crankshaft sensor ring.
55. NOTE: RH timing chain removed for clarity.
NOTE: If the engine front cover is not secured within 4 minutes, 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 sealant along the head-to-block surface and the oil pan-to-block surface as specified.
56. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
57. Tighten the 15 front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).
58. NOTE: RH shown, LH similar.
Install the RH and LH engine mounts and the 6 bolts.
^ Tighten to 70 Nm (52 ft. lbs.).
59. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
60. Using the special tools, install the front oil seal.
61. NOTE: If not secured within 4 minutes, 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 sealant to the Woodruff key slot on the crankshaft pulley.
62. Using the special tool, install the crankshaft pulley.
63. NOTE: Use special tool 303-009 or suitable strap wrench to hold the pulley.
Tighten the crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Rotate an additional 90 degrees (1/4 turn).
64. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, 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.
NOTE: The silicone must be applied on the groove along the retainer plate.
Apply 4 mm (0.16 inch) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
65. Install the rear oil seal retainer and loosely install the 6 bolts.
66. Tighten the 6 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
67. CAUTION: Make sure the O-ring seal is in place and not damaged. A missing or damaged O-ring seal can cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new 0-ring seal. Lubricate the O-ring seal with clean engine oil.
Install the oil pump screen and pickup tube spacer.
^ Tighten to 25 Nm (18 ft. lbs.).
68. Position the oil pump screen and pickup tube, and install the 3 bolts.
1 Tighten to 25 Nm (18 ft. lbs.).
2 Tighten to 10 Nm (89 inch lbs.).
69. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas 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 the sealant at the rear oil seal retainer to cylinder block sealing surface.
70. Apply sealant at the front cover-to-cylinder block sealing surface.
71. Position the new oil pan gasket, the oil pan and the loosely install the 16 bolts.
72. Tighten the 16 bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Rotate an additional 60 degrees.
73. Install the new oil filter adapter gasket, oil filter adapter and the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown.
74. CAUTION: 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.
Install the coolant pump.
1 Lubricate the new 0-ring seal using engine coolant.
2 Position the coolant pump into the engine block.
3 Install the 4 bolts and tighten to 25 Nm (18 ft. lbs.).
75. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
76. Position the accessory drive belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
77. NOTE: If not secured within 4 minutes, 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 sealant in 2 places where the engine front cover meets the cylinder head.
78. Install the new LH gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
79. NOTE: If not secured within 4 minutes, 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 sealant in 2 places where the engine front cover meet the cylinder head.
80. Install the new RH gasket into the valve cover and position on the cylinder head. Tighten the 11 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).