Part 1

Engine

Special Tool(s):

Material:

Engine Upper (Part 1):

Engine Upper (Part 2):

Engine Front:

Engine Lower:

LH Cylinder Head:

RH Cylinder Head:

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

All vehicles

1. NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 5 minutes of sealant application.

Apply a 3 mm (0.11 inch) bead of silicone gasket sealant to the sealing surface of the crankshaft rear seal retainer.

2. Install the rear seal retainer and the 8 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

3. Install the oil pump and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).

4. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).

5. NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.

Install the A/C compressor and the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

6. NOTE: The oil pan and bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 5 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

Apply a 3 mm (0.11 inch) bead of silicone gasket sealant to the sealing surface of the oil pan.
^ Apply a 5.5 mm (0.21 inch) bead of silicone gasket sealant to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.

7. Install the oil pan and the 16 bolts.
^ Tighten the bolts in the sequence shown to 3 Nm (27 inch lbs.).
^ Loosen the bolts 180 degrees.

8. Align the oil pan to the cylinder block and A/C compressor.
^ Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.

9. Tighten the oil pan bolts in the sequence shown.
^ Tighten the large bolts (1-14) to 24 Nm (18 ft. lbs.).
^ Tighten the small bolts (15 and 16) to 10 Nm (89 inch lbs.).

10. Install the A/C compressor mounting stud and nut.
^ Tighten the stud to 9 Nm (80 inch lbs.) and the nut to 25 Nm (18 ft. lbs.).

11. Install the coolant pump and the 8 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

12. Install the knock sensor (KS) and the 2 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).

13. NOTE: Apply clean engine coolant to the O-ring seals prior to installation.

Using new O-ring seals, install the coolant tube.

14. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 3: Tighten 90 degrees.
^ Stage 4: Tighten 90 degrees.
^ Stage 5: Tighten 90 degrees.

15. Install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).

16. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 3: Tighten 90 degrees.
^ Stage 4: Tighten 90 degrees.
^ Stage 5: Tighten 90 degrees.

17. Install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).

18. CAUTION: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

Position the crankshaft dowel pin in the 9 o'clock position.

19. CAUTION: The valve tappets must be installed in their original positions.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

NOTE: LH shown, RH similar.

Install the valve tappets.

20. CAUTION: The camshafts must remain in the neutral position during installation.

NOTE: Coat the camshafts with clean engine oil prior to installation.

Position the camshafts onto the RH cylinder head in the neutral position as shown.

21. CAUTION: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the 8 camshaft caps and the 16 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

22. CAUTION: The camshafts must remain in the neutral position during installation.

NOTE: Coat the camshafts with clean engine oil prior to installation.

Position the camshafts onto the LH cylinder head in the neutral position as shown.

23. CAUTION: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the 8 camshaft caps and the 16 bolts.
^ Tighten in the sequence shown to 10 Nm (89 inch lbs.).

24. CAUTION: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage can occur.

NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size.

25. Install the RH primary timing chain guide and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).

26. Install the RH secondary timing chain tensioner and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).

27. NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Rotate the RH camshafts to the top dead center position and install the special tool on the flats of the camshafts.

28. Assemble the RH variable camshaft timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
^ Align the colored links with the timing marks.

29. Position the RH secondary timing assembly onto the camshafts.

30. Install 2 new bolts and the original washer. Tighten in 4 stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 10 Nm (89 inch lbs.).
^ Stage 4: Tighten 90 degrees.

31. Remove the lockpin from the RH secondary timing chain tensioner.

32. Install the LH secondary timing chain tensioner and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).

33. NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Rotate the LH camshafts to the top dead center position and install the special tool on the flats of the camshafts.

34. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
^ Align the colored links with the timing marks.

35. Position the LH secondary timing assembly onto the camshafts.

36. Install 2 new bolts and the original washer. Tighten in 4 stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 10 Nm (89 inch lbs.).
^ Stage 4: Tighten 90 degrees.

37. Remove the lockpin from the LH secondary timing chain tensioner.

38. Rotate the crankshaft clockwise 60 degrees to the top dead center position (crankshaft dowel pin at 11 o'clock).

39. Install the crankshaft timing chain sprocket.