Part 3

Engine


















Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










Timing Drive Components










Lower Engine Block (View 1)










Lower Engine Block (View 2)









NOTICE: 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, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

53. Install the RH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






54. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the RH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.






55. 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.






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





57. Install the new VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt and the original washer. Tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 10 Nm (89 lb-in).

- Stage 4: Tighten 90 degrees.






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





59. Install the LH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






60. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the LH camshafts to the TDC (Top Dead Center) position and install the Camshaft Holding Tool on the flats of the camshafts.






61. Assemble the LH VCT (Variable Camshaft Timing) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
- Align the colored links with the timing marks.






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





63. Install the new VCT (Variable Camshaft Timing) bolt and the exhaust camshaft bolt and the original washer. Tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 10 Nm (89 lb-in).

- Stage 4: Tighten 90 degrees.






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





65. Rotate the crankshaft clockwise 60 degrees to the TDC (Top Dead Center) position (crankshaft dowel pin at 11 o'clock).





66. Install the crankshaft timing chain sprocket.





67. Install the upper LH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).






68. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT (Variable Camshaft Timing) assemblies and the crankshaft sprocket.






69. Install the lower LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






70. Install the primary timing chain tensioner arm.





71. Reset the primary timing chain tensioner.
1. Release the ratchet detent.

2. Using a soft-jawed vise, compress the ratchet plunger.

3. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a suitable lockpin.






72. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
Install the primary tensioner and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).

- Remove the lockpin.






73. As a post-check, verify correct alignment of all timing marks.
- There are 48 links between the RH intake VCT (Variable Camshaft Timing) assembly colored link (1) and the LH intake VCT (Variable Camshaft Timing) assembly colored link (2).

- There are 35 links between the LH intake VCT (Variable Camshaft Timing) assembly colored link (2) and the 2 crankshaft sprocket colored links (3).






74. Inspect the VCT (Variable Camshaft Timing) housing seals for damage and replace as necessary.





75. NOTE: RH shown, LH similar.

NOTE: During removal, the O-ring seal may remain on the cylinder head. If so, remove the O-ring seal from the cylinder head, inspect the seal (replace as necessary) and install the O-ring seal on the VCT (Variable Camshaft Timing) housing.
Inspect the VCT (Variable Camshaft Timing) housing-to-cylinder head O-ring seals for damage and replace as necessary.






76. NOTICE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this instruction will result in severe engine damage.

Install the LH VCT (Variable Camshaft Timing) housing and the 3 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






77. NOTICE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this instruction will result in severe engine damage.

Install the RH VCT (Variable Camshaft Timing) housing and the 3 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






78. Install the Alignment Pins.