Part 2
Engine
Engine Induction System
Engine - Front End and Lower End
Engine - Flexplate and Engine Lubrication
Engine - Upper End
Assembly
Engines with ratcheting timing chain tensioners
45. Remove the paper clip from the LH timing chain tensioner.
Engines with non-ratcheting timing chain tensioners
46. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
All engines
47. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
48. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
49. 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 lb-ft).
Engines with ratcheting timing chain tensioners
50. Remove the paper clip from the RH timing chain tensioner.
Engines with non-ratcheting timing chain tensioners
51. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
All engines
52. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
53. Rotate and camshaft until the lobe is in the upward position.
54. Install the Valve Spring Compressor Spacer between the valve spring coil to prevent valve stem seal damage.
55. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Install the 16 hydraulic lash adjusters in their original locations (4 shown).
56. 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 Valve Spring Compressor.
2. Compress the valve spring.
3. Install the 16 camshaft roller followers in their original locations.
57. Remove the Valve Spring Compressor Spacer.
58. NOTICE: Only use hand tools when removing or installing the spark plugs or damage may occur to the cylinder head or spark plug.
Install all 8 spark plugs.
- Tighten to 18 Nm (159 lb-in).
59. Install the crankshaft sensor ring.
60. NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE: RH timing chain removed for clarity.
Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
61. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
62. Tighten the 15 front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
63. NOTE: RH shown, LH similar.
Install the RH and LH engine mounts and the 6 bolts.
- Tighten to 70 Nm (52 lb-ft).
64. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
65. Using the Crankshaft Front Oil Seal Installer, Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the front oil seal.
66. NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply sealant to the Woodruff key slot on the crankshaft pulley.
67. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
68. NOTE: Use the Strap Wrench to hold the crankshaft pulley.
Install the bolt and washer and tighten the crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Rotate an additional 90 degrees (one-fourth turn).
69. NOTICE: Make sure the O-ring seal is in place and not damaged. A missing or damaged O-ring seal may cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-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 lb-ft).
70. Position the oil pump screen and pickup tube, and install the 3 bolts.
1. Tighten to 25 Nm (18 lb-ft).
2. Tighten to 10 Nm (89 lb-in).
71. Install the new oil filter adapter gasket, oil filter adapter and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft) in the sequence shown.
72. NOTICE: 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 O-ring seal using clean engine coolant.
2. Position the coolant pump into the engine block.
3. Install the 4 bolts and tighten to 25 Nm (18 lb-ft).
73. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
74. Position the accessory drive belt idler pulley and install the bolt.
- Tighten to 25 Nm (18 lb-ft).
75. NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply sealant in 2 places where the engine front cover meets the cylinder head.
76. 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 lb-in).
77. NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 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 lb-in).
79. Install the Knock Sensor (KS) and the nut.
- Tighten to 20 Nm (177 lb-in).
80. NOTE: Lubricate the O-ring seal with clean engine coolant.
Inspect the O-rings seals. Install new seals, if necessary.
81. Install the coolant bypass tube.
82. Install the ground strap on the rear of the RH cylinder head.
1. Install the stud bolt and tighten to 25 Nm (18 lb-ft).
2. Install the ground strap.
3. Install the retaining nut and tighten to 10 Nm (89 lb-in).
83. Install the insert into the LH cylinder head.
84. NOTE: Align the gasket locator tabs to slots in cylinder head.
Install the new intake manifold gaskets, intake manifold and hand-tighten the 8 bolts at the locations shown.
85. Install the 8 ignition coils and tighten the 8 bolts (4 shown).
- Tighten to 6 Nm (53 lb-in).
86. Install the intake manifold crash bracket bolt and loosely install the bolt and the stud bolt.
87. Install the thermostat.
88. Install the coolant outlet adapter and loosely install the 2 bolts.
